®

User
Manual
SmartPAC ® 2
Press Automation Control
with WPC 2000 Clutch/Brake Control
® ®
includes optional DiPro PAC and ProCam PAC
1128600
Rev. N November 2015

Tech Support Hotline 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 DA70482 www.wintriss.com

 Requirements You Must Meet
When Installing and Using the Wintriss Clutch/Brake Control
The Wintriss Clutch/Brake Control (WPC 2000) is designed solely for controlling operation of part-revolution metal
stamping presses. Before installing or using WPC 2000, be sure you understand and follow these requirements:

! DANGER
FULL REVOLUTION MECHANICAL POWER PRESSES AND OTHER MACHINES CANNOT BE STOPPED IN MID-
STROKE OR MID-CYCLE
 DO NOT use WPC 2000 clutch/brake control on full-revolution clutched machinery or other equipment that cannot be
stopped at any point in its stroke or cycle.
 Use WPC 2000 clutch/brake control only on part-revolution clutched mechanical power presses as defined in OSHA
1910.217 (b) (7). Refer also to ANSI B11.1-2009.
 Use WPC 2000 clutch/brake control only on rotating machinery that can be stopped at any point in its stroke or cycle.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
IMPROPER SAFEGUARDING
 Ensure that the press on which WPC 2000 clutch/brake control is used meets all of the OSHA and ANSI regulations
for safeguarding press systems in installation and use. WPC 2000 is not in itself a safeguarding device. Wintriss
takes no responsibility for injury if safeguarding devices are not installed or working properly.
 Install any two-hand control used as a safety device at least the safety distance away from the hazardous area; safety
distance is defined in the OSHA and ANSI regulations. Verify at each shift change that any moveable two-hand
control used as a safety device is located at least the safety distance away from the hazardous area.
 Install any light curtain or curtains at least the safety distance away from the hazardous area; safety distance is
defined in the OSHA and ANSI regulations.
 Install other safeguarding devices as needed to ensure operator safety. Follow the machine guarding requirements of
OSHA standard 1910.217 and any other regulations and standards that apply. Test safeguarding devices for correct
installation and operation after installation and after any modification or repair.
 Ensure that guarding is properly installed to prevent access to the machine over, under or around any guarding
device.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
MORE OPERATORS THAN OPERATOR STATIONS
 Ensure that there are the same number of active Operator Stations as there are operators, if the press is not equipped
with properly installed and operating light curtains.
 During setup, lockout/tagout the press if there are more operators than Operator Stations.
 Verify at every shift change that there are the same number of active Operator Stations as there are operators, if the
press is not equipped with properly installed and operating light curtains.
FAILURE TO COMPLY WITH THESE INSTRUCTIONS WILL RESULT IN DEATH OR SERIOUS INJURY.

! DANGER
NON-SAFETY OUTPUTS USED FOR SAFETY FUNCTIONS
Use auxiliary outputs and cam channels for non-safety functions only. They cannot protect personnel from a moving
hazard.
Failure to comply with these instructions will result in death or serious injury.

Read additional ! DANGER and ! WARNING notices on following pages.

 ! DANGER
IMPROPER INSTALLATION, USE OR MAINTENANCE
 Ensure that the machinery complies with OSHA regulations 1910.217 and ANSI B11.1-2009.
 Follow all procedures in this manual. Perform only the tests and repairs listed in this manual. Use only factory-
supplied replacement parts. Ensure that all safety procedures are followed during installation and operation of WPC
2000.
 Wire and install WPC 2000 and other equipment according to the requirements of OSHA 1910.147 Control of
Hazardous Energy (Lockout/ Tagout).
 Lockout/Tagout the press during all installation, modification, repair or maintenance procedures.
 Ensure that the dual safety valve used on the press complies with OSHA 1910.217 (b) (7) (xi). Contact manufacturer
to verify compliance of your model.
 Ensure that any foot control complies with OSHA 1910.217 (b) (7) (x).
 Ensure that WPC 2000 clutch/brake control is installed, tested and repaired by qualified personnel.
 Wire, install and maintain WPC 2000 clutch/brake control in accordance with the applicable safety standards. Carry
out all inspection procedures in OSHA 1910.217
 Install and maintain your machine guarding system according to OSHA standard 1910.217, ANSI B11.1, ANSI B11.19
and any other regulations and standards that apply. Ensure that guarding is properly installed to prevent access to the
machine over, under or around any guarding device.
 Perform all installation verification and checkout tests after installation and after any modification or repair of the WPC
2000 clutch/brake control. Correct any problems before using the press.
 Maintain all presses as stated in the applicable regulations. Wintriss takes no responsibility in cases where stopping
mechanisms of machinery or other devices are not maintained or do not meet the applicable regulations or standards.
 Ensure that supervisors, die-setters, maintenance persons, machine operators, foremen, and any others responsible
for operation of the machinery have read and understood all instructions for use of the WPC 2000 clutch/brake control.
 DO NOT use touch buttons for any safeguarding use.
Failure to comply with these instructions will result in death or serious injury.
x

! WARNING
MACHINERY NOT CONFIGURED OR WORKING PROPERLY
 Ensure that the press on which WPC 2000 clutch/brake control is used meets the machine guarding requirements of
OSHA standard 1910.217 and any other regulations and standards that apply.
 DO NOT operate a press equipped with WPC 2000 clutch/brake control if the machine or any of its stopping
mechanisms is not in proper working order.
Failure to comply with these instructions could result in death or serious injury.

! WARNING
OTHER EQUIPMENT CONTINUING TO OPERATE
 Ensure that all operators and other affected personnel know which equipment may continue to operate and which will
not. Equipment that operates with the machinery connected to WPC 2000 clutch/brake control may continue to
operate after the press has received a stop signal.
Failure to comply with these instructions could result in death or serious injury.

! WARNING
ELECTRIC SHOCK HAZARD
 Turn off and disconnect power from WPC 2000 clutch/brake control, the press and any other machinery it is
connected to before making any wiring connections. This includes power to the press’s motor.
Failure to comply with these instructions could result in death or serious injury.

The enforcement of the above requirements is beyond Wintriss’s ability to control. For proper WPC 2000
operation, it is your responsibility to follow these requirements and any other requirements that may be
specific to your machinery.
 Changes for Revision N of the
SmartPAC 2 with WPC 2000 User Manual (1128600)
This revision of the SmartPAC 2 user manual covers SmartPAC 2 software version 13.81 and
higher and WPC 2000 software version 6.00 and higher. The changes include:
• Revised mounting dimensions for the WPC 2000 enclosure (see Figure 2-4, page 2-8)
• Revised instructions for setting the input check voltage switch (see page 2-55)
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
WPC 2000 and Control Reliability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
SmartPAC 2 with WPC 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
SmartPAC 2 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
WPC 2000 Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
SmartPAC 2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
WPC 2000 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Resolver-based Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
SmartPAC 2 Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-6
WPC 2000 Operator Station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-8
SmartPAC 2 Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-9
Sensors Available for DiProPAC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
ProCamPAC Programmable Cams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
SmartPAC 2’s Three Modes of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
SmartPAC 2 with WPC 2000 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . .1-12

Chapter 2. Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Installation Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-3
Connecting Wires to Terminal Block Connectors. . . . . . . . . . . . . . . . . . . . . . . .2-5
Terminating Cable Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-6
Checking the Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Installing WPC 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-7
Mounting the Control Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Wiring the Control Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Connecting AC Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Installing WPC 2000 without Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Installing a Dual Safety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Installing Air Pressure Sensors or Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Installing Operator Station(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Wiring a User-built Operator Station. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
Installing a Light Curtain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Installing the Resolver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
Installing the Overrun Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Wiring WPC 2000 User Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Connecting Other Wintriss Products to WPC 2000. . . . . . . . . . . . . . . . . . . . . . . . 2-34
Installing WPC 2000 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-34
Wiring the Lockout Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-34
Wiring Auxiliary Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-35
Wiring Operator Mode Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Wiring a Foot Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Installing a One-hand Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-39

Table of Contents i
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Wiring a Keylock Switch to Prevent Changes to WPC 2000 Settings . . . . . . . . . . 2-43

Installing Flywheel Speed Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-43
Mounting and Wiring the Bar Control Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
Wiring Automatic Single-stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Wiring Automatic Continuous On-demand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46
Installing SmartPAC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Mounting the SmartPAC 2 Control Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-47
Installing SmartPAC 2 as a Panel Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-48
Wiring between WPC 2000 and SmartPAC 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-50
Connecting SmartPAC 2 to a Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-55
Installing SmartPAC 2 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Adding or Upgrading DiProPAC or ProCamPAC . . . . . . . . . . . . . . . . . . . . . . . . . 2-56
Connecting DiPro Sensor Interface to SmartPAC 2 . . . . . . . . . . . . . . . . . . . . . . . . 2-61
Connecting Programmable Cam Channels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-63
Setting Up High-speed Version of SmartPAC 2 with WPC 2000 . . . . . . . . . . . . . 2-70
Wiring a Remote Reset Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Wiring a Sensor-Disabled Output (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-70
Setting Up SmartPAC 2 with WPC 2000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Turning on Power to SmartPAC 2 and WPC 2000 . . . . . . . . . . . . . . . . . . . . . . . . . 2-71
Problems at Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-73
Verifying Installation of DiProPAC and ProCamPAC . . . . . . . . . . . . . . . . . . . . . . 2-74
Initializing WPC 2000 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-75
Creating and Loading a Test Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-76
Checking and Setting the Direction of Resolver Rotation . . . . . . . . . . . . . . . . . . . 2-77
Zeroing the Resolver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-78
Setting the Top-stop “On” Angle and Installing the Overrun Magnet . . . . . . . . . . 2-78
Installing Revised Firmware in WPC 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-85
Performing Checkout Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-87
WPC 2000 Power Supply Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
Checking Safeguarding Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-90
Checking Dual Safety Valve (DSV) Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-91
Checking the Emergency-stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-92
Checking the Top-stop Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
System Static Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-93
Anti-tiedown Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-96
Anti-repeat Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-97
Shadow Light Curtain Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-98
Single-stroke Mode Test with Light Curtain(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-99
Single Stroke Mode Test without Light Curtain(s). . . . . . . . . . . . . . . . . . . . . . . . 2-102
Continuous Mode Test with Light Curtain(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-103
Continuous Mode Test without Light Curtain(s) . . . . . . . . . . . . . . . . . . . . . . . . . 2-106
Foot Switch Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-108
One-hand Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-110
Bar Mode Control Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-112
Checking Operation of the User Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
Checking Cam Channels (ProCamPAC Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
What Next? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113
Wiring Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-113

ii Table of Contents
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Chapter 3. SmartPAC 2 Keyboard, Displays and Operating

Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Comparing SmartPAC 2 with Original SmartPAC . . . . . . . . . . . . . . . . . . . . . . .3-2
SmartPAC 2 Keyboard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3
Stroke Select Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Number Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
CLEAR Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Cursor Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
HELP Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
ENTER Key. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
RESET Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Program/Run Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Hot Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
SmartPAC 2 Display Layout in Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
Selecting an Item on a Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
SmartPAC 2 Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
Initialization Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-21
Screen Capture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-23
Screen Capture in SmartPAC 2 Main Versions Earlier than V 5.3.1. . . . . . . . . . . 3-23
Screen Capture in SmartPAC 2 Main Versions V 5.3.1 and Later . . . . . . . . . . . . 3-25

Chapter 4. SmartPAC 2 Initialization Mode . . . . . . . . . . . . . . . . . 4-1

Entering and Exiting Initialization Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
Initializing WPC 2000 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
RESOLVER ZERO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Moving the Ram to Top Dead Center (TDC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Setting the Resolver Zero Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5
Position Sensor Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Resolver Motion Mode (Normal Motion – Link Motion) . . . . . . . . . . . . . . . . . . . . 4-6
Angle Wheel Rotation (Clockwise – Counterclockwise) . . . . . . . . . . . . . . . . . . . . 4-6
Tool Number Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Counter Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Counter Increment Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
INSTALLED OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-9
PRESS NAME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
SELECT CAM NAMES (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
AUTO ADVANCE and Slow RPM (Optional). . . . . . . . . . . . . . . . . . . . . . . . .4-12
Calculating the Auto Advance Constant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Setting Auto Advance Constants and Slow RPM . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
SET GLOBAL CAMS (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-15
CUSTOM SENSOR NAMES (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-17

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SENSOR ENABLE MODE (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

Selecting Sensor Enable Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Enabling Setup Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
TOOL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
PRESS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
User Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-24
Press Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Press Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
Input Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44
SECURITY ACCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
Setting Security Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
Changing Passwords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50
Additional Security . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
BACKUP/RESTORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Backing Up Tools to a USB Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-52
Restoring Tools from a USB Disk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54
SETUP DATA COMMS (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
SETUP NETWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
E-MAIL FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57
SMARTVIEW FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
SETUP E-MAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-58
CHANGE NETWORK SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
PRESS TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-60
DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-61
COMMUNICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-62
SET CLOCK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
SAVE TO USB DISK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
UPDATE FIRMWARE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
Using SmartPAC 2 with a Link-motion Press . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
Setting Link Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Using a ServoFeed Interface with Link Motion . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-66
Using a Computer Keyboard to Enter Names . . . . . . . . . . . . . . . . . . . . . . . . . 4-68

Chapter 5. SmartPAC 2 Program Mode . . . . . . . . . . . . . . . . . . . 5-1

Entering and Exiting Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
TOOL MANAGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Creating a New Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Copying an Existing Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Copying Tool Template to a New Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Loading a Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Changing Settings for a Loaded Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Deleting a Tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Tool Program Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
TOOL NAME or TOOL ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
COUNTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

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Setting Preset Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11

Changing Count Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Clearing the Total Hits Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Setting Batch Counter Output and Increment Modes . . . . . . . . . . . . . . . . . . . . . . 5-13
Setting Counter Increment Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Setting Parts per Stroke or Strokes per Part. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Setting Batch Pre-Load Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-15
DIE PROTECTION (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-16
Understanding Sensor Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Programming Sensor Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Programming DiProPAC 32 Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
CAM SWITCH (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-38
Selecting a Cam Channel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
Making an ON/OFF Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
Setting Multiple ON/OFF Cycles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-41
PRESS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-48
TOOL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-50
SENSOR ENABLE/DISABLE & STATUS (Optional) . . . . . . . . . . . . . . . . . .5-52
Viewing Sensor Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-52
Enabling or Disabling All Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53
Turning a Sensor Off or On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-53

Chapter 6. SmartPAC 2 Run Mode . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Entering and Exiting Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Loading a Tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2
Programming Hot Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-3
Settings Locked, or Password Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4
Displaying Multiple Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5
Opening the Crankshaft Angle Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
DISABLE (ENABLE) SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-6
COUNTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-8
DIE PROTECTION (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-9
Adjusting the Ready Signal for Green Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11
Adjusting the Stroke Preset for Green Special Sensors. . . . . . . . . . . . . . . . . . . . . 6-13
Viewing the Sensor Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Show Sensor Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Adjusting DiProPAC 32 Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
CAM SWITCH (Optional). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-18
Viewing Cam Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
Viewing the Global Cam Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Viewing the Cam Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
BRAKE MONITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-20
Determining the Stopping Time of Your Press . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Performing the 90× Stop-time Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Calculating the Safety Distance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-23

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PRESS CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29

Adjusting Program Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-29
Displaying Overrun Sensor On/Off Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
TOOL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-32
ERROR/EVENT LOG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-33
LOAD NEW TOOL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-34
MESSAGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
Sending E-mail to Wintriss Technical Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
TOGGLE HOT KEYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Operating the Press . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Responding to an Interrupted Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
Selecting Operating Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-39
Operating the Press in Inch Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
Operating the Press in Single-stroke Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
Operating the Press in Automatic Single-stroke Mode . . . . . . . . . . . . . . . . . . . . . 6-48
Operating the Press in Continuous Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Operating the Press in Automatic Continuous On-demand Mode . . . . . . . . . . . . . 6-51
Operating the Press in Bar Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Multiple Operator Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53

Chapter 7. Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Responding to Fault Messages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Lockout Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Brake Monitor Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Brake Warning LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Stop Time Exceeded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Messages for Press Control Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Resolver Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Operational Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Inter-processor Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
Input Buffer Test Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Air Pressure Limits Exceeded. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
Component Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Customized Status Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
Light Curtain Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-16
Emergency-stop Circuit Driver Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Top-stop Circuit Driver Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17
Shadow Light Curtain Input Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18
DSV Interface and Lockout Relay Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Loss of Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Internal Timing Input Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Top-stop and Overrun Setting Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Overrun Limit Switch Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Overrun Limit Switch Test Angle Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Overrun Limit Switch Setting Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Internal Memory Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23

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Counter Preset Reached Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-23

Messages for Equipment or Brake Monitor Problems . . . . . . . . . . . . . . . . . . .7-24
Messages for Programming Problems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-27
Messages for Sensor Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-28
Miscellaneous Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-30
Troubleshooting Using the Error/Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31
Resetting Ross DM2 DSV Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-31

Appendix A. Extracts from OSHA Regulations and ANSI

Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Extracts from OSHA Regulation 1910.217. . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Extracts from ANSI Standards for Presence-sensing Devices and Two-hand
Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

Appendix B. Specifications for User-built Operator Stations . . . .B-1

Run Button Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Switch Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2

Appendix C. SmartPAC Preventive Maintenance (PM) Monitor

(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C-1
About SmartPAC PM Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Comparison with Traditional Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . C-1
How the PM Monitor Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Examples of How to Use the PM Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Installing the PM Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
For New Systems from the Factory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
For Existing Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Using the PM Monitor in Initialization Mode. . . . . . . . . . . . . . . . . . . . . . . . . . C-4
How to Get into SmartPAC Initialization and PM Monitor . . . . . . . . . . . . . . . . . . C-4
Initializing the PM Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-6
Assigning a New PM Password Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
Select PM Item Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-8
Using the PM Monitor in Run mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
How to Get into SmartPAC Run mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-12
A Tool Number Must Be Loaded Before Switching to Run Mode . . . . . . . . . . . . C-12
Viewing and Modifying PM Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-13

Appendix D. Updating SmartPAC 2 Firmware . . . . . . . . . . . . . . . .D-1

Updating Firmware Using a USB Disk. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Installing Updated Firmware from USB Disk to SmartPAC 2 . . . . . . . . . . . . . . . . D-2
Downloading Updated Firmware from the Wintriss Server . . . . . . . . . . . . . . . . . . D-7

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Installing Firmware from a Replacement Compact Flash (CF) Card . . . . . . . . D-9

Appendix E. SmartView Remote Viewing and E-mail Setup . . . . E-1

Network Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Network Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Plugging in the Network Cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Programming Network Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Changing Network Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Installing SmartView . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-6
Checking Explorer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6
Installing SmartView on your Computer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8
SmartView Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-10
Setup Page. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-10
Main Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-11
Press Status Information Page . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-12
Remote Messaging. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-13
E-mail Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-14
SmartView Ping Utility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-15

Appendix F. Upgrading from Original SmartPAC to SmartPAC 2 F-1

Backing Up Tools on Original SmartPAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
Removing SmartPAC 1 and Mounting SmartPAC 2 . . . . . . . . . . . . . . . . . . . . . F-3
Wiring the SmartPAC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-4
AC Wiring on SmartPAC 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-12
Restoring Tools to SmartPAC 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-12
System Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-14

Appendix G. Replacing SmartPAC 2 PC Board. . . . . . . . . . . . . . . G-1

Unpacking the Replacement Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
Installing the Replacement Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2

Appendix H. Reporting Downtime and Scrap to SFC. . . . . . . . . . H-1

Machine States to Which SFC Logs Press Time . . . . . . . . . . . . . . . . . . . . . . . . H-1
SmartPAC 2 Downtime Reporting Features . . . . . . . . . . . . . . . . . . . . . . . . . . . H-2
Forced Idle Dialog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-2
Backfilling vs. Forward Filling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-2
Putting the Press “Back on Line” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-3
Forced Error Dialog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-4
Persist Dialog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-5
Single-stroke Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-6
Reset Strokes Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-6

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Setting up SmartPAC 2 to Report Downtime . . . . . . . . . . . . . . . . . . . . . . . . . . H-7

Making Downtime Reporting Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-7
Programming Downtime Reasons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-12
Documenting Downtime on the Dialog Menu . . . . . . . . . . . . . . . . . . . . . . . . H-16
Documenting Downtime in Response to the Forced Dialog Message . . . . . . . . . H-16
Documenting Downtime in Other Situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-19
Ending a Job . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-20
Creating Hot Keys for Dialog Menu Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . H-21
Reporting Scrap and Good Parts to SFC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-22
Making Scrap Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-22
Adjusting the Good Parts Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-25

Appendix I. Reporting Downtime and Scrap to LETS . . . . . . . . . I-1

Machine States to Which LETS Logs Press Time . . . . . . . . . . . . . . . . . . . . . . . I-1
SmartPAC 2 Downtime Reporting Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-2
Forced Idle Dialog Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-2
Backfilling vs. Forward Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-2
Putting the Press “Back on Line” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-3
Forced Error Dialog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-4
Persist Dialog Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-5
Single-stroke Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-6
Reset Strokes Counters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-6
Setting up SmartPAC 2 to Report Downtime . . . . . . . . . . . . . . . . . . . . . . . . . . . I-6
Making Downtime Reporting Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-7
Programming Downtime Reasons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-11
Documenting Downtime on the Dialog Menu . . . . . . . . . . . . . . . . . . . . . . . . . I-14
Documenting Downtime in Response to the Forced Dialog Message . . . . . . . . . . I-14
Documenting Downtime in Other Situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-17
Creating Hot Keys for Dialog Menu Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . .I-18
Reporting Scrap and Good Parts to LETS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-19
Making Scrap Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .I-20
Adjusting the Good Parts Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-23

Appendix J. Option 1 User Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . J-1

Installing the Option 1 Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-3
Wiring Option 1 User Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5
Changing User Input Stop Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-8
Viewing the Status of User Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-9
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-10
Option 1 User Input Setup Sheet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-12

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . GL-1

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Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IN-1

Wintriss Manuals

SmartPAC 2 Setup Sheets

Figures at End of Manual

Figure 1. WPC 2000 and SmartPAC 2 System Wiring
Figure 2. WPC 2000 Operator Station Wiring
Figure 3. WPC 2000 External Wiring
Figure 4. WPC 2000/Shadow V Wiring
Figure 5. WPC 2000 Dual Operator Station Wiring
Figure 6. Stop/Start Motor Control Station with Lockout Wiring
Figure 7. WPC 2000 OEM Operator Station with Separate One-hand Control Wiring
Figure 8. WPC 2000 Operator Station with Separate One-hand Control Wiring
Figure 9. DiProPAC Sensors 1-16 to DSI 2 Wiring
Figure 10.DiProPAC Sensors 17-32 to DSI 2 Wiring
Figure 11.ProCamPAC 16 to Cam Output Wiring
Figure 12.SmartPAC 2 Loopback Wiring Connections
Figure 13.Cross-checked User Interlocks with Positive Action Interlocks
Figure 14.WPC 2000 Shadow VI Wiring
Figure 15.WPC 2000 Shadow VI Integration Wiring
Figure 16.WPC 2000 Herion DSV Wiring
Figure 17.WPC 2000 Ross DSV Wiring
Figure 18.WPC 2000 Operating Mode Output Wiring
Figure 19.WPC 2000 and SmartPAC 1 System Wiring
Figure 20.WPC 2000 and Shadow VII Wiring
Figure 21.Shadow VII DIN Control WPC 2000 Wiring
Figure 22.WPC 2000 Ross DM2 DSV Wiring
Figure 23.WPC 2000 and Shadow 8 Control Box Wiring
Figure 24.WPC 2000 and Shadow 8 Wiring
Figure 25.WPC 2000 Plus Option 1 User Input External Wiring

List of Figures
Figure 1-1. SmartPAC 2 Front Panel .............................................................................................. 1-7
Figure 1-2. Operator Station Components (Side-mounted Run/Inch Palm Buttons) ...................... 1-8
Figure 2-1. Installation Overview ................................................................................................... 2-4
Figure 2-2. Correct Way to Attach Wires to Terminal Block Connectors ...................................... 2-6
Figure 2-3. Connecting Shield Drain Wire to Ground Stud ............................................................ 2-6
Figure 2-4. WPC 2000 Enclosure: Mounting Dimensions ............................................................. 2-8
Figure 2-5. AC Input Wiring Connections .................................................................................... 2-10
Figure 2-6. WPC 2000 Mounting Plate: Mounting Dimensions ................................................... 2-11
Figure 2-7. Air Pressure Sensor .................................................................................................... 2-13

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Figure 2-8. Pre-wired Operator Stations Showing Mute Lamp Connections ................................2-17
Figure 2-9. Wiring Steps to Modify Operator Station for WPC 2000 ..........................................2-18
Figure 2-10. Pre-wired Operator Station with Side Run Buttons: Mounting Dimensions ..............2-19
Figure 2-11. Pre-wired Operator Station with Top Run Buttons: Mounting Dimensions ..............2-19
Figure 2-12. Unwired Operator Station: Mounting Dimensions .....................................................2-20
Figure 2-13. Resolver: Mounting Dimensions ................................................................................2-26
Figure 2-14. WPC 2000 Main Processor Board: Location of Important Components ...................2-28
Figure 2-15. Overrun Sensor Magnet Placement: Dwell as a Function of Shaft Diameter ............2-30
Figure 2-16. Overrun Sensor Magnetic Switch: Installation Example ............................................2-30
Figure 2-17. WPC 2000 Operator Mode Outputs: Wiring Example ...............................................2-37
Figure 2-18. One-hand Control Switch: Mounting Dimensions .....................................................2-40
Figure 2-19. One-hand Control Switch Base: Mounting Dimensions .............................................2-41
Figure 2-20. Wiring Connections in One-hand Control Switch (Switch Cover, Bottom View) .....2-42
Figure 2-21. Installing the LMCS and Magnets ..............................................................................2-44
Figure 2-22. Bar Control Enclosure: Mounting Dimensions ..........................................................2-45
Figure 2-23. SmartPAC 2 Mounting Dimensions: Enclosure .........................................................2-47
Figure 2-24. SmartPAC 2 Mounting and Cutout Dimensions: Panel Mount ..................................2-49
Figure 2-25. SmartPAC 2 Board: Location of Components ...........................................................2-51
Figure 2-26. Wiring AC to Terminal Block, Inside Enclosure, Top Right .....................................2-53
Figure 2-27. Input Check Switch (S101) .........................................................................................2-55
Figure 2-28. DiProPAC and ProCamPAC Boards Installed on SmartPAC 2 Board ......................2-57
Figure 2-29. DiProPAC Boards (8-, 16-, and 32-Sensor): Location of Components ......................2-58
Figure 2-30. ProCamPAC Boards (8- and 16-Channel): Location of Components ........................2-58
Figure 2-31. ProCamPAC Output Assembly ..................................................................................2-65
Figure 2-32. Cam Outputs Board ....................................................................................................2-66
Figure 2-33. Connector TB302 and TB303 for Wiring Relays to Equipment ................................2-68
Figure 2-34. Installing Suppressors Across an AC Load ................................................................2-69
Figure 2-35. Installing a Diode Across a DC Load .........................................................................2-69
Figure 2-36. SmartPAC 2 Startup Screen ........................................................................................2-72
Figure 2-37. SmartPAC 2 Main Program Menu ..............................................................................2-72
Figure 2-38. Main Initialization Menu ............................................................................................2-73
Figure 2-39. Installed Options Screen .............................................................................................2-75
Figure 2-40. Overrun Sensor Magnet Installation Worksheet .........................................................2-81
Figure 2-41. WPC 2000 LED Indicator Map (Center- or Right-mounted Board) ..........................2-89
Figure 3-1. SmartPAC 2 with WPC 2000 Front Panel ....................................................................3-1
Figure 3-2. Differences Between SmartPAC 2 and Original SmartPAC ........................................3-2
Figure 3-3. SmartPAC 2 Keyboard .................................................................................................3-3
Figure 3-4. Stroke Select Key Switch .............................................................................................3-3
Figure 3-5. Number Keys ................................................................................................................3-4
Figure 3-6. Numeric Entry Window (Left); Alphabetic Entry Window (Right) .............................3-4
Figure 3-7. Alphanumeric Entry Window .......................................................................................3-5
Figure 3-8. Clear Key ......................................................................................................................3-5
Figure 3-9. Cursor Keys ..................................................................................................................3-6
Figure 3-10. Highlighted Item on Run Menu ....................................................................................3-6
Figure 3-11. Cam Channel Timing: On=0°, Off=0° .........................................................................3-8
Figure 3-12. Cam Channel Timing: On=239°, Off=0° .....................................................................3-9
Figure 3-13. Cam Channel Timing: On=239°, Off=270° .................................................................3-9
Figure 3-14. HELP Key ...................................................................................................................3-10
Figure 3-15. ENTER Key ................................................................................................................3-10
Figure 3-16. RESET Key .................................................................................................................3-11

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Figure 3-17. Program/Run Key Switch ........................................................................................... 3-11

Figure 3-18. Function Keys ............................................................................................................. 3-12
Figure 3-19. Hot Keys Programmed on Main Run Menu ............................................................... 3-13
Figure 3-20. SmartPAC 2 Display, Run Mode ............................................................................... 3-14
Figure 3-21. Main Run Menu with “CAM SWITCH” Highlighted ............................................... 3-14
Figure 3-22. SmartPAC 2 Operating Modes, Showing Main Menus ............................................. 3-15
Figure 3-23. Initialization Mode Main Menu ................................................................................. 3-17
Figure 3-24. Navigation Example: Initialization Mode ................................................................. 3-18
Figure 3-25. Program Mode Main Menu ........................................................................................ 3-19
Figure 3-26. Navigation Example: Program Mode ........................................................................ 3-20
Figure 3-27. Run Mode Main Menu ............................................................................................... 3-21
Figure 3-28. Navigation Example: Run Mode ............................................................................... 3-22
Figure 4-1. Main Initialization Menu .............................................................................................. 4-1
Figure 4-2. “Resolver Zero” Screen ................................................................................................ 4-4
Figure 4-3. Position Sensor Screen ................................................................................................. 4-5
Figure 4-4. Installed Options Screen ............................................................................................... 4-9
Figure 4-5. Select Language Screen ................................................................................................ 4-9
Figure 4-6. Alphabetic Entry Window .......................................................................................... 4-10
Figure 4-7. Cam Channel Name Menu (16-Channel ProCamPAC) ............................................. 4-11
Figure 4-8. Cam Channel Name Selection Screen ........................................................................ 4-11
Figure 4-9. Auto Advance Menu .................................................................................................. 4-12
Figure 4-10. Global Cams Menu ..................................................................................................... 4-16
Figure 4-11. Global Cam Timing Type Screen ............................................................................... 4-16
Figure 4-12. Custom Sensor Names Screen .................................................................................... 4-17
Figure 4-13. Die Protection Mode Selection Menu ........................................................................ 4-18
Figure 4-14. Tool Information Setup Screen .................................................................................. 4-20
Figure 4-15. Tool Information Name Screen .................................................................................. 4-20
Figure 4-16. Tool Information Units Selection Screen ................................................................... 4-21
Figure 4-17. Tool Information Setup Screen with Sample Entries ................................................. 4-23
Figure 4-18. WPC Initialization Menu ............................................................................................ 4-23
Figure 4-19. Press Control User Interlock Menu ............................................................................ 4-24
Figure 4-20. Select Stop Name Screen ........................................................................................... 4-26
Figure 4-21. Press Control Parameter Menu ................................................................................... 4-27
Figure 4-22. Initialize Parameters Warning Message ..................................................................... 4-34
Figure 4-23. Press Control Option Switch Menu ............................................................................ 4-35
Figure 4-24. S102 Option Switch OFF and ON Settings ................................................................ 4-42
Figure 4-25. Display WPC Input Status Screen .............................................................................. 4-44
Figure 4-26. WPC Buttons and Switches Input Status Screen ........................................................ 4-45
Figure 4-27. WPC Estop and Top Stop Input Status Screen ........................................................... 4-45
Figure 4-28. WPC Interlock Group 1 Input Status Screen .............................................................. 4-46
Figure 4-29. WPC Transducer Input Status Screen ........................................................................ 4-46
Figure 4-30. Security Access Menu ................................................................................................ 4-47
Figure 4-31. “Enter Your Password” Screen .................................................................................. 4-49
Figure 4-32. Set Passwords Menu ................................................................................................... 4-51
Figure 4-33. “Enter a New Password” Screen ................................................................................ 4-51
Figure 4-34. Backup/Restore Control Menu ................................................................................... 4-53
Figure 4-35. Backup/Restore Control Menu with Restore Confirmation Window Displayed ....... 4-55
Figure 4-36. Set Communications Menu ........................................................................................ 4-56
Figure 4-37. Network Setup Utility Screen ..................................................................................... 4-57
Figure 4-38. Setup E-mail Screen ................................................................................................... 4-58

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Figure 4-39. Alphanumeric Entry Window with Default Mail Server Displayed ...........................4-59
Figure 4-40. Diagnostics Menu .......................................................................................................4-61
Figure 4-41. Communications Data Viewer Screen ........................................................................4-62
Figure 4-42. Transmit and Receive Data Screen: Combined View (Left), Split View (Right) ......4-62
Figure 4-43. Set the Clock Screen ...................................................................................................4-64
Figure 5-1. Main Program Menu .....................................................................................................5-1
Figure 5-2. Tool Manager Screen ....................................................................................................5-3
Figure 5-3. Numeric Entry Window (Left); Alphanumeric Entry Window (Right) .......................5-3
Figure 5-4. Copy Tool Template Window ......................................................................................5-4
Figure 5-5. “Enter Your Password” Screen .....................................................................................5-6
Figure 5-6. Load Tool Warning Window ........................................................................................5-6
Figure 5-7. “Enter Your Password” Screen .....................................................................................5-7
Figure 5-8. Delete Tool Confirmation Message ..............................................................................5-7
Figure 5-9. Tool Program Menu ......................................................................................................5-8
Figure 5-10. Alphabetic Entry Window ............................................................................................5-9
Figure 5-11. Counters Screen ..........................................................................................................5-10
Figure 5-12. “Enter Your Password” Screen ...................................................................................5-11
Figure 5-13. Change Count Confirmation Window ........................................................................5-12
Figure 5-14. Counter Mode Selections Screen ................................................................................5-13
Figure 5-15. Advanced Counter Mode Selections Screen ...............................................................5-15
Figure 5-16. Die Protection Sensor Menu .......................................................................................5-16
Figure 5-17. Ready Signal Programming for a “Green” Sensor .....................................................5-18
Figure 5-18. Ready Signal Programming for a “Green Quick Check” Sensor ...............................5-19
Figure 5-19. Ready Signal Programming for a “Green Constant” Sensor ......................................5-19
Figure 5-20. “Enter Your Password” Screen ...................................................................................5-21
Figure 5-21. Die Protection Sensor Menu with Auto Enable by Tool Counter ..............................5-21
Figure 5-22. Sensor Names Screen ..................................................................................................5-22
Figure 5-23. Custom Sensor Names Screen ....................................................................................5-23
Figure 5-24. Auto Enable by Sensor Counter Screen ......................................................................5-23
Figure 5-25. Sensor Type Screen ....................................................................................................5-24
Figure 5-26. Sensor Stop Type Screen ............................................................................................5-25
Figure 5-27. Critical Angle Programming Screen ...........................................................................5-27
Figure 5-28. Ready Signal Programming Screen ............................................................................5-28
Figure 5-29. Green Special Sensor Stroke Count Screen ................................................................5-29
Figure 5-30. Sensor Settings Screen ................................................................................................5-30
Figure 5-31. Sensor Summary Screen .............................................................................................5-31
Figure 5-32. Tool Program Menu with DIPROPAC 1-16 and DIPROPAC 17-32 Items ...............5-32
Figure 5-33. Die Protection Sensor 17-32 Menu .............................................................................5-33
Figure 5-34. Sensor Names Screen with Stripper Function Highlighted ........................................5-33
Figure 5-35. Sensor Type Screen with “GREEN” Highlighted ......................................................5-34
Figure 5-36. Sensor Stop Type Screen ............................................................................................5-34
Figure 5-37. Sensor Summary Screen Showing Ready Signals for Green Sensors ........................5-35
Figure 5-38. Sensor Settings Screen ................................................................................................5-35
Figure 5-39. Sensor Names Screen with Slug Detection Function Highlighted .............................5-36
Figure 5-40. Sensor Type Screen with “GREEN SPECIAL” Highlighted .....................................5-36
Figure 5-41. Sensor Summary Screen Showing Stroke Counts for Green Special Sensors ...........5-37
Figure 5-42. Sensor Settings Screen ................................................................................................5-37
Figure 5-43. Cam Channel Menu ....................................................................................................5-38
Figure 5-44. “Enter Your Password” Screen ...................................................................................5-39
Figure 5-45. Cam Channel Program Type Menu ............................................................................5-39

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Figure 5-46. Cam Channel On/Off Program Screen ....................................................................... 5-40

Figure 5-47. Cam Channel On/Off Program Screen: One On/Off Arc ........................................... 5-41
Figure 5-48. Cam Channel On/Off Program Screen: Two On/Off Arcs ........................................ 5-42
Figure 5-49. Cam Channel On/Off Program Screen: Three On/Off Arcs ...................................... 5-43
Figure 5-50. Cam Channel Timed Output Program Screen ............................................................ 5-44
Figure 5-51. Cam Channel Auto Advance Program Screen ........................................................... 5-45
Figure 5-52. Cam Channel DSV On Program Screen ..................................................................... 5-46
Figure 5-53. Cam Channel Deletion Confirmation Window .......................................................... 5-47
Figure 5-54. Cam Summary Screen ................................................................................................ 5-47
Figure 5-55. Global Cam Summary Screen .................................................................................... 5-48
Figure 5-56. Press Control Parameters Screen ................................................................................ 5-49
Figure 5-57. “Enter Your Password” Screen .................................................................................. 5-49
Figure 5-58. Tool Information Screen ............................................................................................ 5-51
Figure 5-59. “Enter Your Password” Screen .................................................................................. 5-51
Figure 5-60. Sensor On/Off Status .................................................................................................. 5-52
Figure 5-61. “Sensor Turned Off” Message ................................................................................... 5-54
Figure 6-1. Main Run Menu ............................................................................................................ 6-1
Figure 6-2. No Tool Loaded Warning Window .............................................................................. 6-2
Figure 6-3. Main Run Menu, Showing Hot Keys Programmed ..................................................... 6-3
Figure 6-4. Hot Keys Instruction Window ...................................................................................... 6-4
Figure 6-5. “Enter Your Password” Screen .................................................................................... 6-5
Figure 6-6. Display All Errors Message Window ........................................................................... 6-5
Figure 6-7. Crankshaft Angle Window Displayed on Main Run Menu ......................................... 6-6
Figure 6-8. Main Run Menu with SENSORS ENABLED Display ................................................ 6-7
Figure 6-9. Disable Sensors Confirmation Message ....................................................................... 6-7
Figure 6-10. Counters Screen ............................................................................................................ 6-8
Figure 6-11. Counters Screen with “Reload Batch Counters” Function ........................................... 6-9
Figure 6-12. Die Protection Menu (Run Mode) .............................................................................. 6-10
Figure 6-13. “Sensor Turned Off” Message ................................................................................... 6-10
Figure 6-14. Ready Signal Programming Screen ............................................................................ 6-11
Figure 6-15. Sensor Status Screen .................................................................................................. 6-14
Figure 6-16. Main Run Menu with DIPROPAC 1-16 and DIPROPAC 17-32 Items Shown ........ 6-15
Figure 6-17. Die Protection Sensor Menu for Sensors 17-32 ......................................................... 6-16
Figure 6-18. Ready Signal Programming Screen, Run Mode ......................................................... 6-16
Figure 6-19. Green Special Sensor Stroke Count Screen, Run Mode ............................................ 6-17
Figure 6-20. Cam Switch Menu ...................................................................................................... 6-18
Figure 6-21. Cam Timing Screen .................................................................................................... 6-19
Figure 6-22. Stop Time Status Screen ............................................................................................. 6-21
Figure 6-23. View of Light Curtains and Press Showing Safety Distance ..................................... 6-23
Figure 6-24. Press Control Parameters Screen ................................................................................ 6-30
Figure 6-25. Press Control Parameters Screen with Shown Overrun Angles Window .................. 6-31
Figure 6-26. Tool Number Information Screen .............................................................................. 6-32
Figure 6-27. Error/Event Log .......................................................................................................... 6-34
Figure 6-28. Tool Manager Screen ................................................................................................. 6-35
Figure 6-29. Load Tool Warning Window ..................................................................................... 6-35
Figure 6-30. Messaging Screen: List of Recipients ........................................................................ 6-36
Figure 6-31. Messaging Screen: List of Messages .......................................................................... 6-37
Figure 6-32. Sample E-mail to Wintriss Tech. Support .................................................................. 6-37
Figure 6-33. Toggle Hot Keys 1 and 2 Menu Items ....................................................................... 6-38
Figure 6-34. Mode Select Menu ...................................................................................................... 6-39

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Figure 7-1. Error Code Window ......................................................................................................7-2

Figure 7-2. Counter Preset Message Window .................................................................................7-2
Figure 7-3. WPC 2000 Display Showing Fault Code .....................................................................7-5
Figure 7-4. Ross DM2 DSV Showing Reset Button .....................................................................7-32
Figure C-1. “PM Monitor” Highlighted on SmartPAC 2 Initialization Menu ................................ C-4
Figure C-2. PM Password Screen ................................................................................................... C-5
Figure C-3. PM Password Screen Showing Password Retrieval Number ...................................... C-6
Figure C-4. PM Entry Screen .......................................................................................................... C-7
Figure C-5. Initialize PM Screen ..................................................................................................... C-7
Figure C-6. Initialize Warning Screen ............................................................................................ C-8
Figure C-7. PM Monitor Screen ...................................................................................................... C-9
Figure C-8. List of Available PM Names Screen ............................................................................ C-9
Figure C-9. Alphanumeric Display Superimposed over PM Names Screen ................................ C-10
Figure C-10. Tracking Units Selection Screen ................................................................................ C-10
Figure C-11. Superimposed Number Display ................................................................................. C-11
Figure C-12. Programmed PM Item: Example ............................................................................... C-11
Figure C-13. “PM Monitor” Highlighted on SmartPAC 2 Run Menu ............................................ C-12
Figure C-14. Run Mode Screen Showing PM Monitor in “Normal” Status Mode ........................ C-13
Figure C-15. Run Mode Screen Showing “Slide Adjust Motor” in “Alert” Mode ......................... C-14
Figure D-1. Firmware Load Menu with “XFER FROM USB DISK” Highlighted ........................ D-3
Figure D-2. Firmware Load Menu with “LOAD NEW FIRMWARE” Highlighted ...................... D-4
Figure D-3. Firmware Load Menu with Yellow Status Window ....................................................D-5
Figure D-4. SmartPAC 2 Display with “Loading Firmware” Message .......................................... D-6
Figure D-5. Firmware Load Menu with “RELOAD CURRENT FIRMWARE” Highlighted .....D-10
Figure D-6. Firmware Load Menu with Yellow Status Window ..................................................D-10
Figure D-7. SmartPAC 2 Display with “Loading Firmware” Message ........................................ D-11
Figure E-1. Internet Explorer Window with “Internet Options” Selected ...................................... E-6
Figure E-2. Internet Options Screen ............................................................................................... E-7
Figure E-3. Security Tab with “Custom Level” Button .................................................................. E-7
Figure E-4. SmartView Introductory Page ..................................................................................... E-8
Figure E-5. SmartView Setup Page ................................................................................................ E-8
Figure E-6. Mabry Winsock ActiveX Control Window ................................................................. E-9
Figure E-7. SmartView Main Page ............................................................................................... E-10
Figure E-8. SmartView Main Page with Status of Multiple Presses Shown ................................ E-12
Figure E-9. Press Status Information Page ................................................................................... E-13
Figure E-10. SmartPAC 2 Remote Message ................................................................................... E-14
Figure E-11. Email Setup Page ....................................................................................................... E-15
Figure E-12. Mabry Internet Ping Window .................................................................................... E-16
Figure E-13. Ping Utility Window .................................................................................................. E-16
Figure E-14. Ping Utility Window with Example of a Successful Ping ......................................... E-17
Figure E-15. Ping Utility Window with Examples of Two Unsuccessful Pings ............................ E-17
Figure F-1. Backup/Restore Control Menu .....................................................................................F-2
Figure F-2. SmartPAC 2 AC Wiring (Inside Enclosure, Top Right) ............................................F-12
Figure F-3. Backup/Restore Control Menu with Restore Confirmation Message Displayed .......F-13
Figure G-1. SmartPAC 2 PC Board ................................................................................................G-3
Figure G-2. Firmware Load Menu with “RELOAD CURRENT FIRMWARE” Highlighted .......G-5
Figure H-1. Forced Idle Dialog Mode Time Line (Downtime Reason Backfilled) ........................ H-3
Figure H-2. Forced Idle Dialog Mode Time Line (Downtime Reason Forward Filled) ................. H-4
Figure H-3. Forced Error Dialog Mode Time Line ......................................................................... H-5
Figure H-4. SmartPAC 2 Main Initialization Menu ........................................................................ H-8

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Figure H-5. Set Communications Menu ......................................................................................... H-8

Figure H-6. Dialog Fixed Name Choice Menu ............................................................................. H-13
Figure H-7. Dialog Special Choice Name Menu .......................................................................... H-15
Figure H-8. SmartPAC 2 Run Mode Main Menu with Forced Dialog Message Displayed ......... H-16
Figure H-9. Dialog Menu (“16/16” Dialog Screen Mode) ........................................................... H-17
Figure H-10. Dialog Menu (“32 CUSTOM” Dialog Screen Mode) ............................................... H-17
Figure H-11. Dialog Menu with F2/F3 Option Window Displayed ............................................... H-18
Figure H-12. SmartPAC 2 Run Mode Main Menu with DIALOG MENU Item Selected ............. H-19
Figure H-13. Security Access Menu with CHANGE COUNT and CHG GOOD PRTS CNT
Items Set to “PROGRAM AND RUN MODES” ..................................................... H-22
Figure H-14. Counters Screen with “Scrap Value” Function (F3) Shown ..................................... H-23
Figure H-15. Counters Screen with Scrap Value Entry Window Displayed (30 Items Shown) .... H-23
Figure H-16. Counters Screen with Scrap Value Updated to 30 Items .......................................... H-24
Figure H-17. Counters Screen with Scrap Value Entry Window Displayed (10 Items Shown) .... H-24
Figure H-18. Counters Screen with Scrap Value Updated to 40 Items .......................................... H-25
Figure H-19. Good Parts Counter Adjustment Confirmation Window .......................................... H-26
Figure I-1. Forced Idle Dialog Mode Time Line (Downtime Reason Backfilled) .......................... I-3
Figure I-2. Forced Idle Dialog Mode Time Line (Downtime Reason Forward Filled) .................. I-4
Figure I-3. Forced Error Dialog Mode Time Line ..........................................................................I-5
Figure I-4. SmartPAC 2 Main Initialization Menu ......................................................................... I-7
Figure I-5. Set Communications Menu ........................................................................................... I-7
Figure I-6. Dialog Fixed Name Choice Menu ............................................................................... I-11
Figure I-7. Dialog Special Choice Name Menu ............................................................................ I-13
Figure I-8. SmartPAC 2 Run Mode Main Menu with Forced Dialog Message Displayed ........... I-15
Figure I-9. Dialog Menu ................................................................................................................ I-15
Figure I-10. Dialog Menu with F2/F3 Option Window Displayed ................................................. I-16
Figure I-11. SmartPAC 2 Run Mode Main Menu with DIALOG MENU Item Selected ............... I-17
Figure I-12. Security Access Menu with CHANGE COUNT and CHG GOOD PRTS CNT
Items Set to “PROGRAM AND RUN MODES” ....................................................... I-19
Figure I-13. Counters Screen with “Scrap Value” Function (F3) Shown ....................................... I-20
Figure I-14. Counters Screen with Scrap Value Entry Window Displayed (30 Items Shown) ...... I-20
Figure I-15. Counters Screen with Scrap Value Updated to 30 Items ............................................ I-21
Figure I-16. Counters Screen with Scrap Value Entry Window Displayed (40 Items Shown) ...... I-22
Figure I-17. Counters Screen with Scrap Value Updated to 40 Items ............................................ I-22
Figure I-18. Good Parts Counter Adjustment Confirmation Window ............................................ I-23
Figure J-1. Option 1 Board Installed on WPC 2000 Main Processor Board ...................................J-4
Figure J-2. WPC 2000 Option 1 Board ...........................................................................................J-5
Figure J-3. WPC 2000 Option 1 Board: LED Map .........................................................................J-7
Figure J-4. Change User Interlock Screen .......................................................................................J-9
Figure J-5. Display WPC Input Status Screen .................................................................................J-9

List of Tables
Table 1-1. SmartPAC 2 with WPC 2000 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-12
Table 2-1. Clutch Air Pressure Sensor Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Table 2-2. Counterbalance Air Pressure Sensor Wiring Connections . . . . . . . . . . . . . . . . . . . . . 2-14
Table 2-3. Shadow VII and Shadow 8 Light Curtain Jumper Settings . . . . . . . . . . . . . . . . . . . . 2-23
Table 2-4. WPC 2000 Resolver (TB 106) Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-27

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Table 2-5. Overrun Sensor Switch Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-31

Table 2-6. WPC 2000 User Inputs: Stop Types, Fault Codes, and Wiring Connections . . . . . . .2-33
Table 2-7. Lockout Relay Wiring Connections (DSV/Lockout Relay Board) . . . . . . . . . . . . . . .2-34
Table 2-8. Auxiliary Output Wiring Connections and Change Conditions . . . . . . . . . . . . . . . . .2-35
Table 2-9. Option Switch 8 Settings for Auxiliary Output 1 State Change . . . . . . . . . . . . . . . . .2-35
Table 2-10. Foot Switch Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-38
Table 2-11. One-hand Control Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-42
Table 2-12. Flywheel Speed Sensor Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-44
Table 2-13. Bar Control Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-45
Table 2-14. Automatic Single-stroke Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-46
Table 2-15. SmartPAC 2 Resolver (TB101) Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-51
Table 2-16. Communications Wiring: SmartPAC 2 to WPC 2000 . . . . . . . . . . . . . . . . . . . . . . . . .2-52
Table 2-17. Stop and Input Check Circuit Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .2-54
Table 2-18. DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 1-8 . . . . . . . . . . . . .2-61
Table 2-19. DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 9-16 . . . . . . . . . . . .2-62
Table 2-20. DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 17-24 . . . . . . . . . . .2-62
Table 2-21. DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 25-32 . . . . . . . . . . .2-63
Table 2-22. ProCamPAC to Cam Output Assembly TB301 Wiring, Cams 1-8 . . . . . . . . . . . . . . .2-67
Table 2-23. ProCamPAC to Cam Output Assembly TB301 Wiring, Cams 9-16 . . . . . . . . . . . . . .2-67
Table 2-24. Connections to Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-68
Table 2-25. Remote Reset Switch Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-70
Table 2-26. Overrun Sensor Magnet Mounting Angle and Option Switch Settings . . . . . . . . . . . .2-82
Table 2-27. WPC 2000 Main Processor Board, TB101-TB104: Wiring Connections . . . . . . . . .2-114
Table 2-28. WPC 2000 Power Supply (TB105) Wiring Connections . . . . . . . . . . . . . . . . . . . . .2-115
Table 2-29. WPC 2000 Aux. E-stop Relay Board Wiring Connections . . . . . . . . . . . . . . . . . . . .2-115
Table 2-30. WPC 2000 DSV/Lockout Relay Board Wiring Connections . . . . . . . . . . . . . . . . . .2-115
Table 2-31. WPC 2000 AC Power Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-115
Table 2-32. SmartPAC 2 SFI Port (1) and Module Port (2) (TB103) Wiring Connections . . . . .2-115
Table 2-33. SmartPAC 2 Special Port (3) and PACNet Port (4) (TB104) Wiring Connections . .2-115
Table 2-34. SmartPAC 2 Spare 1 Port (5) and WPC Port (6) (TB105) Wiring Connections . . . .2-116
Table 2-35. SmartPAC 2 Spare 3 Port (7) and Spare 4 Port (8) (TB106) Wiring Connections . .2-116
Table 2-36. SmartPAC 2 Aux I/O (TB107) Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . .2-116
Table 3-1. Number Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-5
Table 3-2. Initialization, Program and Run Modes: Entry and Exit Procedures . . . . . . . . . . . . . .3-16
Table 4-1. Instructions for Entering and Exiting Initialization Mode . . . . . . . . . . . . . . . . . . . . . . .4-2
Table 4-2. Numeric and Alphanumeric Tool Number Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
Table 4-3. Abbreviations for Units on Tool Information Setup Screen . . . . . . . . . . . . . . . . . . . .4-22
Table 4-4. Decimal Places and Formats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-22
Table 4-5. Switches 1 and 2 Settings (S101): Top-stop “On” Angle Range . . . . . . . . . . . . . . . . .4-36
Table 4-6. Switch 3 Settings (S101): Enabling Light Curtain Break Mode . . . . . . . . . . . . . . . . .4-36
Table 4-7. Switch 3 Settings (S101): Enabling Foot Control . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37
Table 4-8. Switch 4 Settings (S101): Enabling ACTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-37
Table 4-9. Switch 5 Settings (S101): Prior Act Times for Automatic Modes . . . . . . . . . . . . . . . .4-38
Table 4-10. Switch 6 Settings (S101): Enabling Dual Light Curtains . . . . . . . . . . . . . . . . . . . . . .4-38
Table 4-11. Switch 8 Settings (S101): Top-stop Mode for F and H Errors . . . . . . . . . . . . . . . . . .4-39
Table 4-12. Switch 8 Settings (S101): Auxiliary Output 1 Response to Interrupted Stroke . . . . . .4-40
Table 4-13. Switch 2 Settings (S102): Enabling E-Stop Muting Function . . . . . . . . . . . . . . . . . . .4-42
Table 4-14. Switch 6 Settings (S102): Selecting Concurrent Time for Multiple Op. Stations . . . .4-43
Table 4-15. Security Access Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-48
Table 4-16. Setup E-mail Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-59

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Table 5-1. Instructions for Entering and Exiting Program Mode . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Table 5-2. Additional On/Off Settings, 8-channel Unit: Examples . . . . . . . . . . . . . . . . . . . . . . . 5-41
Table 6-1. Instructions for Entering and Exiting Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Table 6-2. Shadow Light Curtain Response Time and Object Sensitivity . . . . . . . . . . . . . . . . . 6-25
Table 7-1. Fault Codes: Significance of Initial Letter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Table 7-2. Fault Codes for User Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
Table 7-3. Communication Errors: Option at Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31
Table B-1. Operator Station Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Table B-2. Specifications for Operator Station Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Table C-1. Preventive Maintenance Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Table C-2. PM Tracking Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Table D-1. Record of Current Counts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
Table E-1. SmartPAC 2 Board: PS 2 and Y-Cable Configuration . . . . . . . . . . . . . . . . . . . . . . . . . E-4
Table F-1. SmartPAC 1 to SmartPAC 2 Wiring Changes: Main Power . . . . . . . . . . . . . . . . . . . . F-6
Table F-2. SmartPAC 1 to SmartPAC 2 Wiring Changes: Zero Cam . . . . . . . . . . . . . . . . . . . . . . F-6
Table F-3. SmartPAC 1 to SmartPAC 2 Wiring Changes: Input Check, E-Stop, and Top Stop . . F-6
Table F-4. SmartPAC 1 to SmartPAC 2 Wiring Changes: Resolver Port . . . . . . . . . . . . . . . . . . . F-7
Table F-5. SmartPAC 1 to SmartPAC 2 Wiring Changes: Position Sensor (If Used) . . . . . . . . . . F-7
Table F-6. SmartPAC 1 to SmartPAC 2 Wiring Changes: DiProPAC, 8-Channel . . . . . . . . . . . . F-7
Table F-7. SmartPAC 1 to SmartPAC 2 Wiring Changes: DiProPAC, 16-Channel . . . . . . . . . . . F-8
Table F-8. SmartPAC 1 to SmartPAC 2 Wiring Changes: ProCamPAC, 8-Channel . . . . . . . . . . F-8
Table F-9. SmartPAC 1 to SmartPAC 2 Wiring Changes: ProCamPAC, 16-Channel . . . . . . . . . F-9
Table F-10. SmartPAC 1 to SmartPAC 2 Wiring Changes: WPC Port (Integration Only) . . . . . . . F-9
Table F-11. SmartPAC 1 to SmartPAC 2 Wiring Changes: Remote Dual Op. Station Select
(Optional Remote Switch) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10
Table F-12. SmartPAC 1 to SmartPAC 2 Wiring Changes: WPC Adjustment Lockout Switch
(Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10
Table F-13. SmartPAC 1 to SmartPAC 2 Wiring Changes: Remote Reset (Optional) . . . . . . . . . F-10
Table F-14. SmartPAC 1 to SmartPAC 2 Wiring Changes: AutoSetPAC/WaveFormPAC,
2 or 4 Channel (Integration Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-10
Table F-15. SmartPAC 1 to SmartPAC 2 Wiring Changes: SFI (Optional) . . . . . . . . . . . . . . . . . F-11
Table F-16. SmartPAC 1 to SmartPAC 2 Wiring Changes: MultiPAC (Special Port - Optional) F-11
Table H-1. Set Communications Menu Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-9
Table I-1. Set Communications Menu Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-8
Table J-1. Option 1 User Inputs: Input Type and Stop Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J-2
Table J-2. WPC 2000 Option 1 Board: Wiring Connections, TB601 . . . . . . . . . . . . . . . . . . . . . . .J-6
Table J-3. WPC 2000 Option 1 Board: Wiring Connections, TB602 . . . . . . . . . . . . . . . . . . . . . . .J-6
Table J-4. WPC 2000 Option 1 Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J-10

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

How To Use This Manual

This manual shows you how to install, set up, program, operate, and troubleshoot SmartPAC
2 with WPC 2000 including the optional DiProPAC and ProCamPAC modules.
Chapter 1 provides an overview of the operation and features of SmartPAC 2 and WPC 2000.
Chapter 2 shows you how to install SmartPAC 2 with WPC 2000.
Chapter 3 shows you how to use the SmartPAC 2 with WPC 2000 displays and keyboard.
Chapter 4 shows you how to use SmartPAC 2 in Initialization mode, which is the mode you
select to make settings that apply to SmartPAC 2/WPC 2000 operation for all tools.
Chapter 5 shows you how to use SmartPAC 2 in Program mode, which is the mode you select
to program settings that apply to SmartPAC 2/WPC 2000 operation for individual tools.
Chapters 6 shows you how to use SmartPAC 2 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 and WPC 2000 faults.
Appendix A provides OSHA regulations and ANSI standards pertaining to the use of
presence-sensing devices for point-of-operation guarding on mechanical power presses.
Appendix B provides the safety standards you must meet when building your own Operator
Station.
Appendix C shows you how to use the optional PM (Preventative Maintenance) Monitor
available with SmartPAC 2.
Appendix D shows you how to upgrade SmartPAC 2 firmware.
Appendix E shows you how to install and use the SmartView remote viewing utility.
Appendix F provides instructions in upgrading from an original SmartPAC to a SmartPAC 2.
Appendix G shows you how to install a replacement SmartPAC 2 board.
Appendix H shows you how to report downtime and scrap to Wintriss’s ShopFloorConnect
Asset Utilization Software (SFC).
Appendix I shows you how to report downtime and scrap to Wintriss’s Line Efficiency
Tracking Software (LETS).
Appendix J shows you how to install, wire, and troubleshoot WPC 2000 Option 1 user inputs.
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 with WPC 2000.
Figures following the Setup sheets provide wiring diagrams that you can use in conjunction
with the instructions in Chapter 2 to wire SmartPAC 2 with WPC 2000 and its components.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 with WPC 2000 Integration User Manual 1128600

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), electromechanical 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.

This product is covered by US patent #5455848.

Wintriss Controls Group LLC SMARTPAC 2 WITH WPC 2000 INTEGRATION

100 Discovery Way USER MANUAL
Unit 110 1128600
Acton, MA 01720 ©2015 Wintriss Controls Group LLC
Telephone: (800) 586-TECH (8324)
(978) 268-2700
Fax: (978) 263-2048
Internet: http://www.wintriss.com

Table of Contents xxi

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

xxii Table of Contents

Chapter 1. Introduction
SmartPAC 2 is a smart modular interface for multiple press automation functions including
die protection and programmable cam switch. Every SmartPAC 2 provides a control-reliable,
resolver-based brake monitor and extensive counter capabilities. Because SmartPAC 2 is
microprocessor-based, it can monitor or control a variety of functions on every stroke even for
very high-speed presses. SmartPAC 2 features a large, bright color display, a numeric keypad,
and easy-to-use keys to program and run your press. SmartPAC 2 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 control.
SmartPAC 2 can be configured with the following options:
• Up to 32-sensor die protection system
• Up to 16-channel programmable cam switch
• Up to 16-sensor in-die measurement system
• Solid-state dual-microprocessor-based clutch/brake control (WPC 2000)
• Two- or four-input load monitoring
• Automated shut-height and counterbalance control
• Automated press speed and lubrication control
• Servofeed interface
In addition, SmartPAC 2 can be linked to Wintriss’s ShopFloorConnect Asset Utilization
Software (SFC) or Line Efficiency Tracking Software (LETS) for data collection, analysis
and reporting.

WPC 2000 and Control Reliability

WPC 2000 Wintriss Clutch/Brake Control is an easy-to-use, dual-microprocessor-based
system that controls part-revolution mechanical power presses. Housed in a single modular
enclosure, both microprocessors function independently, have different power supplies, and
provide separate information to the operator. As a result of its “dual diverse redundancy,”
WPC 2000 is able to provide optimum clutch/brake control and improved operator safety
while increasing productivity.
WPC 2000 meets or exceeds all ANSI B11.1-2009, OSHA 1910.217, and Canadian Z142-02
standards for Control Reliability, the benchmarks that govern the operation of mechanical
power presses. Control Reliability demands that a single component failure in a clutch/brake
control circuit not prevent the normal stopping action of the press, not create an unintended
stroke, and not allow initiation of a subsequent stroke until the failure has been corrected.

SmartPAC 2 with WPC 2000

SmartPAC 2 integrated with WPC 2000 provides a comprehensive user interface for the
Wintriss Clutch/Brake control, bringing a multitude of press automation functions to one
central location.

Introduction 1-1
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

SmartPAC 2 Standard Features

The following capabilities are standard features on SmartPAC 2:
• 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’s built-in brake monitor constantly checks brake wear by measuring stop time
whenever the press stops and displaying that value in milliseconds. SmartPAC 2 also
displays the number of degrees that it took the press to stop.
• Fault messages appear on the SmartPAC 2 display whenever the press malfunctions,
counter presets are reached, or stopping/starting times exceed set limits. An error/event log
maintains a record of the last 100 errors and events.
• Screen capture capability enables users to easily send the contents of the screen to a PC.
• SmartPAC 2 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 upgrades and enhancements can be installed quickly and easily. Upgrades can
be either downloaded directly to SmartPAC 2 via the local network or mailed to you on a
USB disk.

WPC 2000 Standard Features

WPC 2000 provides the following capabilities as standard features:
• Interrupted Stroke provision. When the press is the Emergency-stopped before the
completion of a stroke by either the operator or an automatic device for personnel or
equipment protection, the message “Interrupted Stroke” flashes on the SmartPAC 2 display,
and WPC 2000 switches to “Two-hand Maintained Single-stroke” mode. To clear the
Interrupted Stroke, the operator pushes both Run/Inch buttons simultaneously and holds
them until the press reaches the top of the stroke. At this point, the “Interrupted Stroke”
message disappears, and WPC 2000 automatically reverts to the original operating mode.
• Customized status codes. Nine user inputs are provided, allowing you to monitor auxiliary
press functions, such as lubrication systems. When one of these functions issues a Stop
command, a unique status code is displayed on the SmartPAC 2 LCD to identify why the
press stopped. Two of the inputs are cross-checked pairs, which you can use for safety
interlocks. If you install the optional Option 1 board, you can connect up to 20 additional
non-control-reliable inputs and up to 4 additional control-reliable, cross-checked input
pairs (see Appendix J).
• 90° stop-time test. This standard feature is required in order to set the correct safety
distance for personnel-guarding devices including light curtains, two-hand controls, and
type-B movable barriers. The test is performed at 90°, the press’s most critical stopping
point, with the press running in Continuous and the heaviest die installed. The results of

1-2 Introduction
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

the test provide the stopping time (Ts) value specified in both OSHA 1910.217 and ANSI
B11.1-2009 (see Appendix A).
• Inputs for multiple Shadow light curtains. WPC 2000 tests up to two Shadow light curtain
inputs every time that the press is started and stopped.
• Micro-inch, a feature that allows you to set the amount of time that the Dual Safety Valve is
open in Inch mode when you push the Run/Inch palm buttons. Normally, in Inch the DSV
is open for only as long as the Run/Inch buttons are depressed. The Micro-inch setting
specifies the length of time the DSV is open regardless of how long the Run/Inch buttons
are held. Allowing finer adjustments than are possible in Inch, Micro-inch is designed to
facilitate setup on high-speed or short-stroke presses.
• Connection of two Operator Stations directly to the WPC 2000. Additional Operator
Stations may be connected. Contact Wintriss Tech. Support for information.
• WPC 2000 Main Processor board with diagnostic LEDs for troubleshooting.

SmartPAC 2 Options
SmartPAC 2 can be configured with the following options:
• DiProPAC. When configured with the DiProPAC option, SmartPAC 2 can monitor up to
32 sensors, allowing detection of malfunctions such as stock buckling, misfeeds, and
improper part ejection.
• ProCamPAC. The ProCamPAC option provides up to 16 programmable cam channels,
enabling SmartPAC 2 to control cam timing for feed, pilot release, air blow-off, lubricator,
and other press equipment. ProCamPAC also includes global cams for press operation
functions, DSV ON channel delay timing, and multiple on/off cycles for a single cam.
• AutoSetPAC or WaveFormPAC. Provides two- or four-channel load monitoring,
protecting your press and dies from overloads and underloads. You can store high, low, and
repeatability setpoints with tool number, display, adjust, and recalculate setpoints, and
compare setpoints to the actual load. With WaveFormPAC, you can also display and save
load signatures and create up to four windows to monitor tonnage at points other than peak.
• RamPAC. Provides automatic control of shut height and counterbalance and cushion
pressures by tool number.
• ProPAC. Provides up to 16 analog, NPN, or PNP inputs that enable you to monitor in-die
dimensions and other process parameters.
• Info Center. Enables die setup sheets and other plant-specific 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 E) must be installed. Documentation of the Info Center option is available at
www.smartpac2.com/SmartView/InfoCenterSetupHelp.htm
• SBR (SmartPAC Backup and Restore). Allows you to back up programmed tool settings to
a Windows laptop PC.
• USB Disk Backup. Allows you to back up tool settings to a USB disk.

Introduction 1-3
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

• High Speed (HSP). Required for presses that run faster than 800 SPM, this option handles
speeds from 14-1600 SPM.
• Bilingual. Provides Run mode screens in both English and a second language which you
select.
• Preventive Maintenance (PM) Monitor. Allows you to track selected press functions
requiring scheduled maintenance and alerts you when maintenance is due.
• PLC Interface. Enables SmartPAC 2 to transmit tool settings to a Programmable Logic
Controller for press automation and auxiliary functions.
• SFC (ShopFloorConnect Asset Utilization Software) or LETS (Line Efficiency Tracking
Software). Data collection software that processes downloaded production information
from SmartPAC 2, generating OEE and other reports.
• Third Party Communications. Allows SmartPAC 2 to transmit real-time and status
information to external software for reporting and other tasks.

WPC 2000 Options

The following options can be added to your WPC 2000:
• Operator Station. The Operator Station is normally the device used to run the press in all
Stroke Select positions. Wintriss provides operator stations with Run/Inch palm switches
mounted on either the top or sides (see Installing Operator Station(s), page 2-16 for
available configurations).
• Dual-monitored Safety Valve (DSV). The DSV controls the flow of air to the press clutch
and brake. Wintriss provides 3/4 in. and 1 in. Ross DM2 DSVs. See Installing a Dual
Safety Valve, page 2-12 for further details.
• System Air Pressure Sensor or Switch. This sensor or switch monitors the system air
pressure. See Installing Air Pressure Sensors or Switches, page 2-13 for additional
information.
• Shadow Light Curtain. The Shadow light curtain is a presence-sensing device that places
an infrared light field between the point-of-operation and the operator. When an object,
like the operator’s hand, enters the sensing field and blocks a light beam, the light curtain
detects the object and issues an Emergency-stop command to the press.
The Shadow light curtain is required for point-of-operation guarding if WPC 2000 is used
with a Foot Switch or in One-hand operating mode. Multiple light curtains can be wired to
a WPC 2000. WPC 2000 tests up to two pairs of Shadow inputs every time that the press is
started and stopped. See Installing a Light Curtain, page 2-22 for more information.
WPC 2000 is designed to be used with a Shadow light curtain. If you order WPC 2000
without a light curtain, the control enclosure does not have a Mode Select switch, and the
unit operates only in Two-hand mode.
The light curtain is placed between the Operator Station and the die space. Shadow’s
mounting-bracket design allows plenty of room for adjustment.
• Counterbalance Air Pressure Switch. Operating identically to the clutch air pressure
switch, this switch is used with the counterbalance air supply on presses equipped with
counterbalances, as required by OSHA regulations.

1-4 Introduction
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

• One-hand Control. A low-force switch that can be used with WPC 2000 running
One-hand/Two-hand/Foot firmware and equipped with a Shadow light curtain guarding the
point of operation. The One-hand Control switch can be mounted on or near the press,
allowing the operator to press the switch as part of his normal hand motion after loading a
part.
• Foot Switch. A device that frees the operator’s hands for increased, fully-guarded
protection and productivity. One-hand/Two-hand/Foot firmware is required, and a Shadow
light curtain must be installed.
• Bar Mode Control. Allows operators and setup personnel to bar the press by hand for die
setting and adjustment. Recommended for smaller-capacity presses of 65 tons or less.
• Automatic Single-stroke (External Trip). Allows feed equipment to signal WPC 2000 to
initiate a stroke upon completion of a feed. This option is useful in applications where the
feed must be completed before the press can be stroked.
• Automatic Continuous On-demand. Allows an external device to signal WPC 2000 to start
the press in Continuous mode and maintain operation in Continuous.
• Auto Compensated Top Stop (ACTS). A feature that automatically adjusts the Top-stop
“On” Angle to an earlier point in the stroke to compensate for increases in press speed.
ACTS is designed specifically for variable-speed presses. See Switch 4 – Enabling Auto
Compensated Top Stop (ACTS), page 4-37 for additional information about this feature.
• Multiple Operator Stations. Two Operator Stations can be connected directly to WPC
2000. If you wish to install more than two Op. Stations, contact Wintriss Tech. Support
(see Installing Multiple Operator Stations, page 2-21).

! DANGER
HAZARDS EXPOSED BY NON-WORKING OPERATOR STATION
• Safeguard the point of operation exposed by the non-working Operator Station when
using multiple Operator Stations. The exposed area near a disabled Operator Station
must be properly guarded.
• Ensure that guarding is properly installed to prevent access to the machine over, under
or around any guarding device.
Failure to comply with these instructions will result in death or serious injury.

NOTICE
Use light curtains in addition to multiple operator stations for best personnel safeguarding.

• Display Configuration Options. WPC 2000 is available without an enclosure. See

page 2-11 for installation instructions.
• Auxiliary E-Stop Output Relay Board. Allows up to three auxiliary devices such as a feed
or transfer to be stopped or prevented from starting when an E-stop button is pressed, a
light curtain is interrupted, or a cross-checked input is open.
If your WPC 2000 has Shadow light curtain muting firmware, you can prevent the auxiliary
E-stop relays from issuing a Stop command if the light curtain is interrupted during the
muted portion of the stroke by setting option switch 2 on switch block S102 on the WPC

Introduction 1-5
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

2000 Main Processor board (see page 4-42). The auxiliary E-stop muting function is
necessary in applications where parts must be ejected through a light curtain. Auxiliary
relay muting does not prevent the auxiliary relays from issuing a Stop command when an
E-stop button is pressed or a cross-checked input is open.
Layout of the Auxiliary E-Stop Output Relay board is shown in Figure 2-14, page 2-28.
Wiring connections are shown in Table 2-29, page 2-115.

Resolver-based Operation
SmartPAC 2 is connected to a resolver mounted on the press that turns one to one (1:1) with
the crankshaft. Like an electrical generator, the resolver has internal windings and works on
the principle of inductance. As the resolver turns, the amplitude and phase of its two outputs
vary. SmartPAC 2 converts this analog signal to a number that specifies the position of the
press crankshaft in degrees.

SmartPAC 2 Front Panel

Programming and operation of SmartPAC 2 is accomplished via the SmartPAC 2 front panel,
which is shown in Figure 1-1, page 1-7. A brief description of each panel component is
provided below.
Display 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).
Program/Run key switch 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.
Stroke Select key switch Allows you to select the operating mode of the press. There are
four settings: Off, Inch, Single-stroke, and Continuous.
Keyboard Consists of cursor keys and a numeric keypad (described
below) that are used with the display to make settings.
Cursor keys 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.
Number keys Enable you to input numeric values such as counter presets or
tool numbers
Function keys 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.
HELP key Enables you to access a help screen that provides information
about the display you are looking at.

1-6 Introduction
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

SmartPAC 2
Wintriss Press Automation Control

PRESS #14
TOOL NUMBER 6160 PART CNTR 449
CAMBIE
AL ESPANOL F1
FLANGE B TWO HAND S.S.
PRESS ANGLE 270
POWER F2

USE THE CURSOR KEYS ENABLE SENSORS

F3
BRAKE TO MAKE SELECTIONS. COUNTERS
WARNING PRESS ENTER TO
ACCESS SELECTION.
DIE PROTECTION
CAM SWITCH
F4
BRAKE MONITOR
TONNAGE/WAVEFORM
PRESS CONTROL
F5
FEED CONTROL
TOOL INFORMATION
F6
270 SHUTHGT/CNTRBAL
ERROR LOG
LOAD NEW TOOL
F7
DIALOG MENU
TOGGLE HOT KEYS 1
F8
SINGLE
INCH
STROKE
CONT 1 2 3 PROG RUN
ENTER
OFF
4 5 6
HELP

7 8 9 RESET

CLEAR
0 .
Figure 1-1. SmartPAC 2 Front Panel

ENTER key When you press this key, SmartPAC 2 accepts the menu item
you have selected or the number you have keyed in.
RESET key 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.
Brake Warning LED An amber LED that flashes when the stopping time of the press
increases to within 10 milliseconds of the preset Stop-time
Limit, alerting the operator that it is time to schedule
maintenance on the brake.
Detailed instructions on how to use the keyboard and display are provided in Chapter 3.

Introduction 1-7
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

WPC 2000 Operator Station

Figure 1-2 identifies the switches and indicator lamps on a Wintriss Operator Station. (The
configuration with side-mounted Run/Inch palm switches is shown.) Functions of Operator
Station components are provided following the figure.

PRIOR ACT PALM TIME EMERGENCY STOP MUTE TOP STOP

switch lamp switch lamp switch

PRIOR PALM GEN TOP

ACT TIME ER MUTE STOP

EM

CY
RUN/ RUN/
INCH INCH

STOP WINTRISS

RUN / INCH
palm switches

Figure 1-2. Operator Station Components (Side-mounted Run/Inch Palm Buttons)

Run/Inch Palm Switches (2)–Initiate press action when both switches are pressed at the
same time (Two-hand mode) or when only the left switch is pressed (One-hand mode).
Prior Act Lamp and Switch–An arming device that must be pressed in Continuous Two-
hand and Continuous Foot operating modes before a stroke can be initiated. When the switch
is pressed, the lamp illuminates for 8 seconds, indicating the interval within which the
operator must press the Run/Inch buttons or Foot Switch in order to stroke the press. Also
used in Automatic Single-stroke operation (see page 6-48).
Emergency Stop Switch–Stops the press immediately when you push it. The switch is not
spring-loaded, so you must pull it back to its original position to clear the emergency stop
(F13) fault (see page 7-8).
Top Stop Switch–Stops the press at the top of its stroke when pressed during Continuous
operation.
Palm Time Lamp–Illuminates when one Run/Inch palm button is depressed, turning off after
the 1/2-second palm time (“synchronous” time in ANSI terminology) on a standalone
Operator Station or the 5-second concurrent time on multiple Operator Stations. The other
palm button on a standalone Op. Station or all pairs of buttons on multiple Operator Stations
must be pressed before the lamp turns off in order to initiate a stroke.
Mute Lamp–Illuminates during muting of the light curtain on the upstroke. Requires
installation of a Shadow light curtain and optional light curtain muting firmware.

1-8 Introduction
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

SmartPAC 2 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, sensor (if DiProPAC is
installed), cam switch (if ProCamPAC 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 for each tool, such as installation notes.
• 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 setup, you can require a special
password for access to the Main Initialization Menu.
• Set Brake Monitor. You set the brake monitor stop time limit to compensate for normal
brake wear and to provide a warning when the brake needs service. When you make a time
setting that is longer than the actual stopping time and the press reaches that stop time limit,
the brake monitor disables the press, alerting you that your brake requires service. In
addition, the Brake Warning LED on the SmartPAC 2 front panel (see Figure 1-1, page 1-7
for location) flashes when press stopping time approaches within 10 milliseconds of the
stop time limit, allowing you to schedule brake maintenance before the press has to be
disabled.
• 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 at 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 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 crankshaft angle at which the error

Introduction 1-9
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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.
• Set timing for cam channels (ProCamPAC Only). You can specify the crankshaft
angle at which to activate your feed pilot release, assembly operations, air cylinders,
transfer devices, lubricators, air blow-off, cut off, loader/unloader controls, and other
equipment that requires precise synchronization with the press. You can also assign a name
to each cam channel.

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 electromechanical sensor can be used with SmartPAC 2 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, contact
Wintriss Controls.
Wintriss makes or sells a wide range of sensors. Those that can be used with SmartPAC 2
with DiProPAC are shown below. Detailed application information is available. Many
sensors made by other manufacturers can also be used.
• Miniature fiberoptic photoelectric sensors—Through-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.

1-10 Introduction
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

ProCamPAC Programmable Cams

! DANGER
PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE
Use SmartPAC 2’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 clutch/brake control or muting of light curtains.
Failure to comply with these instructions will result in death or serious injury.

The optional ProCamPAC module enables you to connect up to eight or sixteen cam channels
to your equipment. ProCamPAC consists of a PC board that you install in your SmartPAC 2
and a separate assembly that contains the relays that open and close on signals from
SmartPAC 2. 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.

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 that control operation of SmartPAC 2 when
any tool is loaded (e.g., the zero position of the resolver, global cams, auto advance
constants, etc.). 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 that control SmartPAC 2
operation for a specific tool (e.g., sensor and cam timing, counter presets, etc.). 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.

Introduction 1-11
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

SmartPAC 2 with WPC 2000 Specifications

SmartPAC 2 with WPC 2000 specifications are shown in Table 1-1.

Table 1-1. SmartPAC 2 with WPC 2000 Specifications

Enclosures SmartPAC 2 Enclosure

12.76 x 11.53 x 5.28 in. (324 x 293 x 134 mm), NEMA 12, shock-mounted.
Weight: 17.4 lbs.
SmartPAC 2 Panel mount
12.3 x 11.3 in. (312 x 287 mm)
WPC 2000 Enclosure
14.00 x 19.62 x 7.00 in. (355.6 x 498.3 x 177.8 mm), NEMA 12,
shock-mounted.
WPC 2000 without Enclosure
Allow 15.5 x 15.5 x 5.5 in. (394 x 394 x 140 mm) for installation.

Equipment Resolver
(Available from 0.75 in. (19 mm) keyed shaft. Rated shaft loading: 200 lb. axial, 200 lb. radial.
Wintriss
Operator Station
Controls)
NEMA 12. Includes two palm buttons, Top-stop, Emergency-stop, and Prior
Act buttons, and palm time and mute lamps. Pre-wired; unwired version also
available.
Dual Safety Valve (DSV)
Available in 0.75 in. (19 mm) or 1 in. (25 mm) Ross DM2 models.
Air Pressure Switch or Sensor
Switch: 12-150 PSI. Sensor: 0-200 PSI, 1-6 Vdc, excitation 24 Vdc. Monitors
clutch air supply pressure.

Electrical SmartPAC 2 Input

115/230 ± 10% Vac 50/60 Hz, 50 VA
Input Check Circuit
12-250 Vac or Vdc
WPC 2000 Input
100-240 ± 10% Vac (universal switching), 50/60 Hz., 75 VA
WPC 2000 Output
24 ± 1% Vdc, 200 mA maximum for customer use including auxiliary outputs.
Power Requirements If Not Using Wintriss AC Power Supply
24 ± 5% Vdc, 2 A. Must be certified to CSA C22.2 No. 234 Standard.

Oper. Temp. 32° to 122° F (0° to 50° C)

Speed 7-800 SPM; 14-1600 SPM optional at reduced accuracy (see SmartPAC 2
Options, below)

1-12 Introduction
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Table 1-1. SmartPAC 2 with WPC 2000 Specifications (Cont.)

Accuracy ± 2/3° (± 1.33° for high speed version–see SmartPAC 2 Options, below)

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)
Brake Warning LED, Power LED

Memory Allows storage of settings for 200 tools

SmartPAC 2 Inputs for resolver, input check circuit, remote reset

Inputs/Outputs 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)

WPC 2000 Resolver

Inputs Overrun limit switch
Two operator stations
DSV monitor
Air pressure switch or sensor (???)
Two pressure sensors: range, 0-200 psi; output, 1-6 Vdc; excitation, 12 Vdc.

Additional Motor
WPC 2000 Forward and reverse contacts
Inputs
Shadow Light Curtains (2)
Checks proper functioning at every stroke initiation and stop.
Customized Status Codes
Seven for E-stop, Top-stop, or E-stop/Lockout
Two cross-checked pairs, one for E-stop or E-stop/Lockout, the other for
E-stop/Lockout only

WPC 2000 DSV

Outputs Two monitored relays, rated 4 A @ 120 Vac, for E-stopping and Top-stopping
press.
Lockout
One monitored relay, rated 4 A @ 120 Vac, for de-energizing motor and other
devices under critical conditions.
Auxiliary Stop Output
Provides a signal to stop auxiliary equipment during an interrupted stroke.

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.

SmartPAC 2 DiProPAC provides up to 32 die protection sensor inputs

Options 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.

Introduction 1-13
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Table 1-1. SmartPAC 2 with WPC 2000 Specifications (Cont.)

SmartPAC 2 ProCamPAC provides up to 16 programmable cam switch output channels

Options Programmable cam output assembly (NEMA 12; holds up to 8 outputs)
(continued) 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
AutoSetPAC* or WaveFormPAC* 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
Display, adjust, recalculate “auto” setpoints and display actual load
Display and save load signatures
Up to 4 windows to monitor tonnage at points other than the peak
(WaveFormPAC only)
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
ProPAC* 12.3 x 14 x 4.3 in. (312 x 356 x 109 mm)
Provides up to 16 analog, NPN or PNP inputs
Ability to store high, low, and repeatability setpoints with tool number
Display and adjust manual or auto setpoints and display actual values
Monitor in-die dimensions and other process parameters
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
High Speed (HSP)
Required for presses with speeds higher than 800 SPM; handles speeds from
14-1600 SPM (see Speed and Accuracy, above)
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

1-14 Introduction
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Table 1-1. SmartPAC 2 with WPC 2000 Specifications (Cont.)

SmartPAC 2 ShopFloorConnect Asset Utilization Software (SFC) or Line Efficiency

Options Tracking Software (LETS)
(continued) 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

WPC 2000 Shadow V, Shadow VI, Shadow VII, or Shadow 8 Light Curtains
Options Heights from 6 to 60 in., scanning ranges from 23’ to 65’. Refer to Shadow
literature for more information.
Firmware
Muting for Shadow light curtain on the upstroke. Two-hand only. One-hand,
two-hand or foot operation**. Automatic Single-stroke (External Trip).
Continuous On-demand. Auto compensated top-stop (ACTS). High Speed
(>500 SPM).
Selector Switches
Mode (One-hand, two-hand, or foot operation**). Micro-inch on/off. Automatic
(single-stroke or continuous on-demand) on/off to slave the press to an
external device. Operator station select for either of two operator stations or
both operator stations.
Auxiliary E-Stop Output Relays
Two monitored relays, rated 4 A @ 120 Vac, for up to three auxiliary devices
(e.g., feed, transfer, etc.), which can be stopped or prevented from starting if
any E-stop button is depressed, any light curtain is interrupted, or any cross-
checked inputs are open.
Foot Switch
Safety switch for foot actuation** (1-hand/2-hand/foot firmware required).
One-hand Control
Control for one-hand actuation** (1-hand/2-hand/foot firmware required).
Counterbalance Air Pressure Switch or Sensor
Switch: 12-150 PSI. Sensor: 0-200 PSI, 1-6 Vdc, excitation 24 Vdc. Monitors
counterbalance air supply (uses one custom input).
Bar Mode Control
Allows manual turning of crankshaft.
Remote Crank-angle Clock Display
Second display can be installed up to 100 ft. away.
Motor Control and Custom Packages
Refer to Press Control/Motor Starter literature, and/or contact your Wintriss
representative or factory for more details.

* Consult product user manual. DSI 2: #1121900; AutoSetPAC: #1101600; WaveFormPAC:

#1109100; RamPAC: #1115200; ProPAC: #1117500; Bilingual (English/Spanish):
#1130600.
** Shadow light curtains required

Introduction 1-15
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

1-16 Introduction
Chapter 2. Installation
! DANGER
IMPROPER INSTALLATION, USE OR MAINTENANCE
• Follow all procedures in this manual. Perform only the tests and repairs listed in this manual.
Use only factory-supplied replacement parts.
• Ensure that WPC 2000 clutch/brake control is installed, tested and repaired by qualified
personnel.
• Wire, install and maintain WPC 2000 clutch/brake control in accordance with the applicable
safety standards. Carry out all inspection procedures in OSHA 1910.217.
• Wire and install all equipment in accordance with the requirements of OSHA 1910.147 Control
of Hazardous Energy (Lockout/Tagout).
• Install and maintain your machine guarding system according to OSHA standard 1910.217,
ANSI B11.1, ANSI B11.19 and any other regulations and standards that apply. Ensure that
guarding is properly installed to prevent access to the machine over, under or around any
guarding device.
• Perform the checkout sequence after installation and after any modification or repair of the WPC
2000 clutch/brake control.
• Lockout/Tagout the press during all installation, modification, repair or maintenance procedures.
• Ensure that supervisors, die-setters, maintenance persons, machine operators, foremen, and
any others responsible for operation of the machinery have read and understood all instructions
for use of the WPC 2000 clutch/brake control.
• Disconnect the “Continuous” mode position of your Stroke Select switch and cover the “CONT”
label on your control if the press is not properly guarded for use in Continuous mode.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
FAULTY INSTALLATION
• Ensure that wiring is correct.
• Use only safety-certified components for safety functions, including interlock switches used in
safety applications.
• Install guarding to prevent access to hazardous areas. Prevent access to hazardous areas
over, under, or around any guarding devices.
• Ensure that there is one active Operator Station for each operator if you are using Two-hand
mode.
Failure to comply with these instructions will result in death or serious injury.

Installation 2-1
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

! 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 wiring 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’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 clutch/brake control or muting of light curtains.
Failure to comply with these instructions will result in death or serious injury.

NOTICE
OPTIONAL MODULES PROCAMPAC AND DIPROPAC INCLUDED IN MANUAL
When you order your SmartPAC 2 with WPC 2000 system, you may include the DiProPAC die
protection and/or ProCamPAC programmable cam switch option. This manual includes
instructions for installing and using both modules. Remember that they are options and might not
be included in your system.
If you ordered SmartPAC with other optional modules such as AutoSetPAC load monitor or
ProPAC process monitor, refer to the user manual for that option for complete details on its
installation and use.

NOTICE
UPGRADING FROM ORIGINAL SMARTPAC
See Appendix F for instructions on upgrading from original SmartPAC to SmartPAC 2.

NOTICE
READ INSTALLATION INSTRUCTIONS BEFORE STARTING INSTALLATION
If you install WPC 2000 and 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
When you have completed installation procedures, perform the tests in the Performing Checkout
Tests section, page 2-87 to ensure that WPC 2000 and SmartPAC 2 are installed correctly and
working properly before proceeding to the Initialization (Chapter 4), Program (Chapter 5), and Run
(Chapter 6) chapters.

2-2 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

NOTICE
LEARN TO USE SMARTPAC 2 BEFORE INSTALLING ON A PRESS
If you have not used SmartPAC 2 before, learn how to initialize and program it before installing it
on a press. On the bench, connect your unit to a resolver (see page 2-24) and to AC power (see
page 2-9) so that you can 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.

NOTICE
PRESS MUST BE AT TDC
Before starting installation, make sure that the die has been removed from the press and the press
ram has been moved to top dead center (TDC). The press must be at TDC when you make final
adjustments for the resolver. The TDC setting should be 0° ±2°. Use a dial indicator on the face
of the ram, if necessary, to ensure that the ram is positioned correctly.

Installation Guidelines
Observe the following guidelines when installing WPC 2000 and SmartPAC 2, referring to
Figure 2-1, page 2-4 when necessary.
• Provide clean input power
Provide a dedicated 120V power circuit from the press control transformer to the WPC
2000 input power connection. Do not power any relays or solenoids from this circuit or
from the auxiliary power terminals on WPC 2000. Doing so may cause erratic press
shutdowns due to electrical noise.
• Separate high- and low-voltage wires
Never run wires for 120V and for lower voltages (e.g., 24V, 60V) inside the same conduit.
For example, the Operator Station cables should not share the same conduit with 120 Vac
wiring. However, power and logic wiring for the light curtain or Dual Safety Valve (DSV)
can be run in the same conduit.
Run flexible, liquid-tight conduit for high-voltage lines (120V power) to a knockout on the
top left of the WPC 2000 enclosure. Run another high-voltage conduit (120 V power, relay
circuits, input check circuit) from a knockout on the top left of WPC 2000 to a knockout on
the top right of the SmartPAC 2 enclosure. 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.
Run a high-voltage conduit for DSV wiring and a a low-voltage conduit for the resolver to
knockouts on the bottom left of WPC 2000. Run a low-voltage conduit for resolver and
communications wires from the lower right of WPC 2000 to the lower left of SmartPAC 2.
The AC power supply wires to SmartPAC 2 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. Do not use the ProCam
output enclosure as a junction box for the AC control wires. Provide a separate junction
box for this purpose.

Installation 2-3
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Overrun limit sensor

Crankshaft

Timing chain

Resolver

Air pressure
switch

Motor
Control

Dual Safety
Resolver, Valve (DSV)
overrun
limit
sensor,
and air
pressure
switch
wiring

DSV
wiring

AC power, E-stop, Top-stop,

input check cirucit wiring
AC high voltage
wiring (from
customer control
transformer)
Wintriss
Clutch/Brake SmartPAC 2
Control

Connections to
option modules,
cam outputs,
DSI 2, etc.

Operator Station Resolver and communications wiring

Figure 2-1. Installation Overview

2-4 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

• Provide NEMA 12 conduit and connections

Because SmartPAC 2 and WPC 2000 are 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 and WPC 2000
The ground wire from SmartPAC 2 should be connected to the main ground point of the
WPC 2000. 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 2-6).
• Install suppressors across inductive loads
All relays, solenoids, or other inductive loads that are controlled by SmartPAC 2 or WPC
2000 must be suppressed. Suppressors should be installed across the load and as close to
the load as possible. See Figure 2-34, page 2-69. Never install a suppressor across relay
contacts. If you do, the suppressor may fail shorted and the equipment controlled by that
relay remain energized. In some cases, suppressors are required in the Top-stop and
Emergency-stop circuits. Additional suppressors (part number 2238801) can be obtained
from Wintriss.

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. Find the correct terminal and loosen the screw over it by turning it counterclockwise (see
Figure 2-2, page 2-6).
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.

Installation 2-5
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Tighten screw to clamp

wire in terminal

Insert wire here

Figure 2-2. Correct Way to Attach Wires to Terminal Block Connectors

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 and WPC 2000 have ground studs on the inside of the enclosure for
terminating cable shields at their point of entry. For each shielded cable, perform the
following steps, referring to Figure 2-3.

Strip cable jacket

as far as end of
Drain wire conduit fitting

Secure drain wire

under nut on
ground stud

Figure 2-3. Connecting Shield Drain Wire to Ground Stud

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.

2-6 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Checking the Press

Before starting the installation, remove the die from the press and check all modes of press
operation. Run the press in Inch, Single-stroke, and Continuous. Make sure the press has
working Top-stop and Emergency-stop circuits. Verification that the press operates and stops
properly is extremely important because WPC 2000 and SmartPAC 2 will be connected to the
press stop circuits. Do not forget to indicate in your electrical prints where WPC 2000 and
SmartPAC 2 are wired in. Set the press ram to top dead center (TDC).

NOTICE
MOVE RAM TO TDC BEFORE INSTALLING WPC 2000 AND SMARTPAC 2
Move the ram to top dead center (TDC) before installing WPC 2000 and SmartPAC 2. Be accurate
when setting the press to TDC. Set to 0° ±2°. Use a dial indicator on the face of the ram if
necessary.

Installing WPC 2000

The following sections show you how to mount and wire the WPC 2000 control enclosure.

Mounting the Control Enclosure

Mount the control enclosure (see Figure 2-4, page 2-8 for mounting dimensions) so that it can
be easily reached to make wiring connections and perform necessary maintenance.
The enclosure does not have to be mounted to the press but can be installed on a free-standing
pedestal, pendant, or column.
For easy access to the interior of the enclosure, make sure that there is enough room to open
the control enclosure door at least 120°.

NOTICE
NON-ENCLOSURE INSTALLATION
See Installing WPC 2000 without Enclosure, page 2-11 for installation instructions if you are
installing WPC 2000 in your own enclosure or console.

Plastic cable ties and self-sticking cable clamps are provided in the accessory parts bag. Use
them to organize the cables and wiring inside the control enclosure.

Installation 2-7
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

14.68 Note: Allow sufficient clearance

(372.8) for opening door
14.28
(362.7)
12.00 7.27
(304.8) (184.5)

17.62
(447.6)

16.88
(428.8)

Dimensions: inches
(mm)

Figure 2-4. WPC 2000 Enclosure: Mounting Dimensions

Wiring the Control Enclosure

WPC 2000 requires the following electrical components:
• Motor forward auxiliary contact (24V)
• Slide adjust monitor circuit (24V)
• Motor stop circuit (110V), if applicable
• Motor reverse auxiliary contact (24V), if applicable
Power to WPC 2000 should be provided by a step-down control transformer capable of
handling 75 VA at 115 Vac ± 10%.
Most of the original controls on the press will be replaced during rewiring except the
disconnect, motor starter, and control transformer. Make sure to rewire so that the motor
starter operates properly.

2-8 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Slide Adjust Considerations

If your press has a motorized slide adjustment for the ram, you must prevent slide adjustment
while the press is running. Connect spare contacts on the slide adjustment switches (i.e., Slide
Adjustment “On” or Slide Adjustment “Up”/“Down” switch) to the WPC 2000 Emergency-
stop circuit or a user interlock to stop the press as soon as the ram adjust switches on. For help
in determining how to connect this wiring, call Wintriss Tech. Support.

Connecting AC Wiring

! 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.

NOTICE
FOR 24 VDC VERSIONS OF WPC 2000:
• Refer to Table 1-1, page 1-12 for DC power requirements
• Wire 24 Vdc directly to connector TB105 on the WPC 2000 Main Processor board (see
Figure 2-14, page 2-28 for location and Figure 16 (Herion DSV), Figure 17 (Ross Serpar
DSV), or Figure 22 (Ross DM2 DSV) at the back of the manual for wiring.)
Connect “+ volts” to pin #90 on TB105
Connect “ground” to pin #89

All wires can be run through flexible, liquid-tight conduit to the control as long as all circuits
are 115V. If your Top-stop circuits and Emergency-stop circuits are low voltage (for
example, 24V), run two conduits–one for 115V wires and one for 24V wires. Be sure to
number all wires so they are consistent with the electrical prints for your press.
Bring the wiring connections for AC power to a convenient point so that you can connect
them to the power terminal block at the top left of the enclosure (see Figure 2-5, page 2-10).
No. 16 wire (No. 14, if local codes require it) is recommended for these circuits with a
minimum 75° C temperature rating.

NOTICE
WPC 2000 AUTOMATICALLY ADJUSTS TO 115 OR 230 VOLT INPUT POWER
You do not need to use a switch or other device to set the level of input power.

To make AC power wiring connections, perform the following steps:

Installation 2-9
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

1. Locate the power supply input terminal block on the back wall at the top left of the
enclosure, as shown in Figure 2-5.

Connect ground wire

to set screw ground
terminal

Neutral
Line

Input Power
Terminal block
LINE
NEUT

Top left corner

inside enclosure

Figure 2-5. AC Input Wiring Connections

2. Determine how you will bring wiring from your 115 or 230 Vac power source to the
enclosure. 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. Run the power wires to the enclosure through flexible, liquid-tight conduit. Because WPC
2000 is rated NEMA 12 (protected against dust and oil), you must use conduit of the same
rating and make proper connections to ensure NEMA 12 protection.
4. Connect the ground wire to the set screw terminal on the roof of the enclosure, referring to
Figure 2-5 and to Figure 16 (Herion DSV), Figure 17 (Ross Serpar DSV), or Figure 22
(Ross DM2 DSV) at the back of the manual.
5. Connect the power wires.
For 115 Vac power, connect the black wire to the LINE terminal and the white wire to
NEUT.
For 230 Vac, connect the black wire to the LINE terminal and the red wire to NEUT.
Strip the wire 1/4 in. from the end. Loosen the screw in the input power terminal block,
insert the stripped portion of the wire, and tighten the screw.
6. Double-check connections.
7. Make all necessary conduit connections to ensure NEMA 12 protection.

2-10 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Installing WPC 2000 without Enclosure

When you order WPC 2000 without enclosure, you receive a Main Processor board, power
supply, and input power terminal block mounted on an aluminum plate (see Figure 2-6 for
mounting dimensions).

2.67 10.65
(67.8) (270.5)
10.00
(254.0) 45o x .125
.090 (3.18)
(2.3) 2.25 7.00 4 places
(57.1) (177.8)

TB105

TB104
Input power
terminal
block

13.00
(330.2)

TB103
12.25
(311.2)

TB102
TB101

TB 106 TB 107 TB 108 TB 109

.312 Allow 1” clearance on top, bottom, and left side .25

(7.92) of mounting plate and above board/power supply. (6.4)
Dimensions: inches ID Allow 2 1/2” clearance on right side (i.e., side to
(mm) 4 places which TB101-TB104 are connected).

Figure 2-6. WPC 2000 Mounting Plate: Mounting Dimensions

The plate has a hole in each corner to facilitate installation of the WPC 2000 board and related
components in your enclosure or console. When installing the mounting plate, be sure to
allow at least 1 in. clearance on top, bottom, and both sides of the plate and above the power
supply and Main Processor board. Allow at least 2 1/2 in. clearance on the right side of the
plate for making wiring connections to terminal blocks TB101-TB104.

Installation 2-11
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

The power supply on the mounting plate is pre-wired to the power terminal, TB105, on the
Main Processor board and to the input power terminal block on the plate. To connect AC
wiring to the input power terminal block, follow the instructions in Connecting AC Wiring,
page 2-9.

Installing a Dual Safety Valve

! DANGER
USER-SUPPLIED DUAL SAFETY VALVE NOT SUITABLE FOR SAFETY USE
Ensure that your dual safety valve meets the applicable safety standards. Contact the valve
manufacturer for information.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
INSTALL DSV CLOSE TO CLUTCH/BRAKE ASSEMBLY TO REDUCE STOPPING TIME
Install the dual safety valve as close as possible to the clutch/brake assembly. Any excess piping
between the valve and the clutch/brake assembly increases the Stopping Time of the press.
Failure to comply with these instructions will result in death or serious injury.

! WARNING
DSV MUFFLER CLOGGING OR LOOSENING
• Clean the DSV muffler periodically. A clogged muffler can degrade Stopping Time.
• Tighten the muffler securely to the valve body. Periodically check to make sure the muffler is
securely installed. Vibration may cause it to loosen and fall. To tighten the muffler, secure the
valve body, hold the muffler with both hands and turn clockwise as tightly as possible without
stripping the threads.
Failure to comply with these instructions could result in death or serious injury.

If you have ordered a Ross or Herion DSV with your WPC 2000, refer to the appropriate
wiring diagram at the end of this manual and to the documentation that came with your valve
to install the DSV. Note the following requirements:
• Ross DM2
To wire the Ross DM2 DSV, refer to figures 18 and 22 at the back of the manual.
The Reset circuit requires that a diode be installed across the coil in the solenoid to provide
noise suppression (see Figure 22). This wiring has already been done for you in the
Hirschmann connector for the 24 Vdc Reset solenoid, which is provided along with two
Hirschmann connectors for the 120 Vac valve solenoids in the Ross DM2 kit.
The Reset solenoid connector comes in two styles. One has a black shell with an electrical
circuit including a diode symbol ( ) printed on it, the other a transparent shell with a red
LED indicator visible inside. You install this connector on the Reset solenoid at one end of
the DSV. The Reset solenoid connector is the only connector at this end of the DSV. The
other two connectors are installed on the two valve solenoids at the other end of the DSV,

2-12 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

which has three connectors altogether, including one for the DSV monitor that is already
installed. You wire the Reset solenoid and valve solenoid connectors to WPC 2000 as
shown in Figure 22.

CAUTION
DO NOT WIRE RESET CIRCUIT TO 110 VAC
The Reset circuit works only on 24 Vdc. Do not wire the Reset circuit to 110 Vac.
Failure to comply with these instructions could result in property damage.

Note that the DM2 Reset circuit is wired to the OFF position on the WPC 2000 Stroke
Select switch (see Figure 18). To reset the Ross DM2 DSV after an F47 error (see
page 7-14), press Reset/Select, and turn the Stroke Select switch to OFF, then back to one
of the other operating modes (i.e., Inch, Single-stroke, or Continuous).
Make sure to install air supply lines that match the inlet port size of the DM2 DSV to
provide sufficient air to reset the unit in case of a fault (see page 7-31).
• Ross Serpar with EP Monitor
This Ross DSV requires a separate user-supplied reset switch. See Figure 17 at the end of
this manual. Also, all jumpers except those shown in the wiring diagram must be removed;
otherwise, the WPC 2000 Main Processor board may be damaged.
• Herion XSZ
Make sure that you wire the Herion DSV monitor between pin #20 and a +24 Vdc output.
See Figure 16 at the end of the manual.

Installing Air Pressure Sensors or Switches

Your SmartPAC 2 with WPC 2000 requires either sensors or switches to monitor clutch air
pressure and counterbalance air pressure if there is a counterbalance. Wintriss offers two
pressure sensors with the unit, one for clutch air pressure, the other for counterbalance air
pressure (see Figure 2-7).

1/4 in. NPT

female threads M12 connector

1 2 3 4 5 6

Figure 2-7. Air Pressure Sensor

The following sections show you how to install air pressure sensors and switches.

Installation 2-13
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Installing a Clutch Air Pressure Sensor

Install and wire a clutch air pressure sensor as follows:

1. Install a filter regulator and lubricator in-line before the clutch air pressure sensor if they
are not already present.
2. Connect shop air to the clutch air pressure sensor input port.
3. Run the cable through flexible, liquid-tight conduit, observing NEMA 12 requirements.
4. Wire the clutch air pressure sensor as shown in Table 2-1 and in Figure 1 at the end of the
manual.

Table 2-1. Clutch Air Pressure Sensor Wiring Connections

WPC 2000 Main Processor Bd.
Pin # Signal Wire Color
32 +24 Vdc Red
33 Main System Air White
34 Analog Ground Black

5. On the WPC 2000 Main Processor board, connect a jumper between pin #8, the Clutch Air
Pressure Switch input, and ground (e.g., pin #54) to ground the input.
6. Set the clutch air pressure sensor to 35 PSI, or the pressure recommended by the press
manufacturer.

Installing a Counterbalance Air Pressure Sensor

Install and wire a counterbalance air pressure sensor as follows if there is a counterbalance:
1. Install a filter regulator and lubricator in-line before the counterbalance air pressure sensor
if they are not already present.
2. Connect shop air to the counterbalance air pressure sensor input port.
3. Run the cable through flexible, liquid-tight conduit, observing NEMA 12 requirements.
4. Wire the counterbalance air pressure sensor as shown in Table 2-2 and in Figure 1 at the
end of the manual.

Table 2-2. Counterbalance Air Pressure Sensor Wiring Connections

WPC 2000 Main Processor Bd.
Pin # Signal Wire Color
42 +24 Vdc Red
43 Counter Balance White
44 Analog Ground Black

2-14 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

5. Set the counterbalance air pressure sensor to the pressure recommended by the press
manufacturer, typically the pressure required for the smallest upper die you plan to use in
this press

NOTICE
USING RAMPAC (SMARTPAC 1 OR 2) TO CONTROL COUNTERBALANCE PRESSURE
If you use RamPAC to control the counterbalance pressure, install a pressure switch and
connect it to WPC 2000 as described in Installing a Counterbalance Air Pressure Switch,
page 2-15.

Installing a Clutch Air Pressure Switch

NOTICE
The clutch air pressure switch is held closed when pressure is applied above the setpoint limit.

Install and wire the clutch air pressure switch as follows:

1. Install a filter regulator and lubricator in-line before the clutch air pressure switch if they
are not already present.
2. Connect shop air to the clutch air pressure switch input port.
3. Run the cable through flexible, liquid-tight conduit, observing NEMA 12 requirements.
4. Wire the normally open terminals of the switch between pin #8 and ground (e.g., pin #54)
on the WPC 2000 Main Processor board, referring to Figure 1 at the end of the manual.
5. Set the clutch air pressure switch to 35 PSI, or the pressure recommended by the press
manufacturer.

Installing a Counterbalance Air Pressure Switch

Install and wire a counterbalance air pressure switch as follows if there is a counterbalance:
1. Install a filter regulator and lubricator in-line before the counterbalance air pressure switch
if they are not already present.
2. Connect shop air to the counterbalance air pressure switch input port.
3. Run the cable through flexible, liquid-tight conduit, observing NEMA 12 requirements.
4. Wire the normally open terminals of the switch to pin # 83 (User Input 4) and ground (e.g.,
pin # 54), referring to Figure 1 at the end of the manual.

NOTICE
If pin #83 has already been assigned to other user-selected auxiliary equipment, then wire
the counterbalance switch contacts across a terminal on the WPC 2000 Main Processor
board that generates an E-stop when the connection to ground is broken. See Wiring
WPC 2000 User Inputs, page 2-31 for more information.

Installation 2-15
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

5. Set the counterbalance air pressure switch to the pressure recommended by the press
manufacturer, typically the pressure required for the smallest upper die you plan to use in
this press.

NOTICE
USING RAMPAC (SMARTPAC 1 OR 2) TO CONTROL COUNTERBALANCE PRESSURE
If you use RamPAC to control the counterbalance pressure, set the WPC 2000
counterbalance pressure switch to the pressure required to balance the empty ram.

Installing Operator Station(s)

! DANGER
NON-WINTRISS OPERATOR STATION MAY NOT MEET SAFETY REQUIREMENTS
• Ensure that the Operator Station is wired correctly.
• Ensure that on any non-Wintriss Operator Station the Run buttons are placed so that two hands
are required to push them at the same time and that buttons cannot be pushed simultaneously
with one hand or with one hand and one elbow.
• Ensure that on any non-Wintriss Operator Station the Run buttons have ring guards or other
means in place to prevent unintentional operation.
• Run all necessary tests to verify that each Operator Station is wired correctly and provides
proper anti-tie-down and anti-repeat protection. Test procedures are provided at the end of this
chapter (see page 2-87).
Failure to comply with these instructions will result in death or serious injury.

The Operator Station should be installed in a location from which the operator can
conveniently run the press. On most gap-frame (OBI or OBG) presses, this will be on the
front of the bolster. For straight-side presses, the Operator Station may be installed on the
press or on a pedestal.
The Operator Station should not be permanently mounted until you have calculated the
correct safety distance (see page 6-23) and performed the applicable checkout (see page 2-87)
tests. When you have finished wiring, you can place the Operator Station temporarily on the
floor or on a cart.
If you are not installing a light curtain, and if you are planning to use the Operator Station as a
two-hand safety device, the Operator Station must be mounted at the correct safety distance
from the nearest pinch point on the press. This distance must be calculated based on the
Stopping Time of your press. See page 6-21 for details. Mounting the Operator Station at the
correct safety distance prevents an operator from leaving the station and reaching the pinch
point before the press stops.
If you are installing a light curtain, the Operator Station must be placed outside the area
guarded by the light curtain. You do not need to calculate a specific safety distance for your
Operator Station since the light curtain now prevents access to the pinch point. You must not,
however, mount the Operator Station between the light curtain and the pinch point.

2-16 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Wiring a Pre-wired Operator Station

Checking Pre-wired Operator Station Wiring

Before connecting your pre-wired Operator Station to WPC 2000, check the wiring to the
mute lamp inside the Operator Station and modify, if necessary, according to the instructions
below. Operator stations shipped as part of WPC 2000 systems should not need modification.
1. Find the mute lamp on the Operator Station, as shown in Figure 2-8.

PRIOR PALM GEN TOP

ER
ACT TIME MUTE STOP

EM

CY
STOP WINTRISS

Pre-wired
Operator Stations Mute Lamp
top view

PRIOR PALM GEN TOP

ER
R MUTE R
ACT TIME STOP
U U
EM

CY

N N
/ /
I I
N N
C C
H STOP H
WINTRISS

Mute Lamp Connections

for WPC 2000
Side-button
Operator Station
Cover, opened,
showing underside
of cover.
(Top-button station
is similar.)

Figure 2-8. Pre-wired Operator Stations Showing Mute Lamp Connections

2. Open the Operator Station, and locate the mute lamp connections on the underside of the
cover.
3. Determine whether you need to modify the mute lamp wiring:
• If your mute lamp wiring looks like panel “E” in Figure 2-9, page 2-18 (i.e., the black
wire is connected, the red-and-white wire not connected), the wiring is correct.
• If your mute lamp wiring looks like panel “A”, follow steps A through E in Figure 2-9
to disconnect the white-and-red wires and connect the black wire.
4. When the mute lamp wiring is correct, connect the Operator Station to WPC 2000.

Installation 2-17
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

A
Pair of white-and-red
wires connected to
one terminal
Examine the mute of the mute lamp
lamp wiring as it
came from the factory.

NOTE:
Orientation of connections
may be different.
Black wire with
connector lug,
not connected
to anything

B C

Disconnect the pair of

white-and-red wires. Free the black wire.

D E

Bend the white-and-red Connect the black wire

wires back on themselves. where you just
Ty-wrap them in place. disconnected the pair
Insulate connector lug of white-and-red wires.
with electrical tape.

Figure 2-9. Wiring Steps to Modify Operator Station for WPC 2000

Making Wiring Connections

To wire a pre-wired Operator Station, perform the following steps:
1. Punch a hole in the Operator Station enclosure for conduit or sealtight.
2. Connect the conduit or sealtight to the hole; then open the Operator Station box.
3. Run the Operator Station cable in the sealtight.
4. Plug the connector end of the cable into the Operator Station.

2-18 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

5. At the other end of the cable, connect the wires to the Main Processor board connector
terminals, as shown in Table 2-27, page 2-114 and Figure 2 at the end of the manual.
6. Mount the Operator Station in a permanent location after performing the applicable
verification and checkout tests and calculating the correct safety distance. Refer to
Figure 2-10 and Figure 2-11 for mounting dimensions.

21.25
(539.8)
16.75
(425.5)

PRIOR PALM GEN TOP

ER
R MUTE R
ACT TIME STOP
U U

EM
4.69

CY
N
/
N
/ 5.50
(119.1) I
N
I
N (139.7)
C C
H H
STOP WINTRISS

5.8
(148)
REF
Dimensions:
inches
(mm)

Figure 2-10. Pre-wired Operator Station with Side Run Buttons: Mounting Dimensions

28.75
(730.3) 16.75
(425.5)

PRIOR PALM G EN TOP

ER
ACT TIME MUTE STOP

4.69
EM

CY

5.50
(119.1) (139.7)
STOP WINTRISS

6.06
(154.0)
Dimensions:
inches
(mm)

Figure 2-11. Pre-wired Operator Station with Top Run Buttons: Mounting Dimensions

Installation 2-19
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Wiring an Unwired Operator Station

! DANGER
OPERATOR STATION MAY NOT MEET SAFETY REQUIREMENTS
• Ensure that the Operator Station is wired correctly.
• Run all necessary tests to verify that each Operator Station is wired correctly and provides
proper anti-tie-down and anti-repeat protection. Test procedures are provided at the end of this
chapter (see page 2-87).
Failure to comply with these instructions will result in death or serious injury.

To wire the unwired Wintriss Operator Station, follow the wiring diagram in Figure 7 at the
end of this manual. Before using your press, be sure to check the wiring carefully, run all the
applicable verification and checkout tests, and calculate the safety distance. You can then
mount the Operator Station in a permanent location, referring to Figure 2-12 for mounting
dimensions.

21.25
(539.8)
16.75
(425.5)

PRIOR GEN TOP

R
U
ACT ER STOP R
U
EM

4.69
CY

N
/
N
/ 5.50
(119.1) I
N
I
N (139.7)
C C
H H
STOP WINTRISS

5.8
(148)
REF Dimensions:
inches
(mm)

Figure 2-12. Unwired Operator Station: Mounting Dimensions

2-20 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Wiring a User-built Operator Station

! DANGER
NON-WINTRISS OPERATOR STATION MAY NOT MEET SAFETY REQUIREMENTS
• Ensure that the Operator Station is wired correctly.
• Ensure that on any non-Wintriss Operator Station the Run buttons are placed so that two hands
are required to push them at the same time and that buttons cannot be pushed simultaneously
with one hand or with one hand and one elbow.
• Ensure that on any non-Wintriss Operator Station the Run buttons comply with the requirements
specified in Table B-2, page B-2.
• Ensure that on any non-Wintriss Operator Station the Run buttons have ring guards or other
means in place to prevent unintentional operation.
• Run all necessary tests to verify that each Operator Station is wired correctly and provides
proper anti-tie-down and anti-repeat protection. Test procedures are provided at the end of this
chapter and at the end of Chapter 3.
Failure to comply with these instructions will result in death or serious injury.

If you build your own Operator Station, refer to Appendix B for applicable safety
requirements. To wire your user-built Operator Station, refer to Figure 7 at the end of the
manual. Before using your press, be sure to check the wiring carefully and run all the
applicable verification and checkout tests. After calculating the correct safety distance, you
can mount the user-built Operator Station in a permanent location.

Installing Multiple Operator Stations

! DANGER
HAZARDS EXPOSED BY NON-WORKING OPERATOR STATION
• Safeguard the point of operation exposed by the non-working Operator Station when using
multiple Operator Stations. The exposed area near a disabled Operator Station must be
properly guarded.
• Ensure that guarding is properly installed to prevent access to the machine over, under or
around any guarding device.
Failure to comply with these instructions will result in death or serious injury.

NOTICE
Use light curtains in addition to multiple Operator Stations for best personnel safeguarding.

You can wire up to two Operator Stations to the WPC 2000 (see Figure 5 at the back of the
manual for dual Op. Station wiring). Make sure that switch 6 on S102 on the WPC 2000 Main
Processor board is set to OFF if you connect dual Operator Stations (see page 4-43).
If you wish to install more than two Operator Stations, contact Wintriss Tech. Support. Do
not order standard Wintriss “Multiple Operator Stations” when installing more than two Op.
Stations. All Operator Stations in a multi-Op.-Station configuration except the Op. Station

Installation 2-21
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

connected to the “A” inputs must contain a Two-hand Control module. When you install
more than two Operator Stations, set switch 6 on S102 to ON.
When wiring dual operator stations, make sure to label each Operator Station correctly.
Install the label “A” prominently on the Operator Station wired into inputs for Operator
Station “A” or “1.” Install the label “B” prominently on the Operator Station wired into inputs
for Operator Station “B” or “2.” Test each Operator Station individually. Confirm that
selector switch position “A” controls Operator Station “A” and selector switch position “B”
controls Operator Station “B.” Also test switch position “Both” to confirm that it controls
both Operator Station “A” and Operator Station “B.”

Installing a Light Curtain

! DANGER
PREVENT OPERATOR FROM STANDING BETWEEN LIGHT CURTAIN AND HAZARDOUS AREA
Ensure that the operator cannot position himself between the light curtain and the hazardous area.
Use another pair of light curtains or a mechanical barrier at knee to waist height to prevent the
operator or a passerby from being “trapped” between the light curtain and the hazard.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
INCORRECT LIGHT CURTAIN INSTALLATION
• Mount the light curtains at the correct safety distance as instructed in Calculating the Safety
Distance, page 6-23. The light curtain will only provide full protection for operators when
mounted at the correct safety distance.
• Install and wire your light curtains correctly, following the instructions in your Shadow manual
and referring to Figures 4, 14, 15, 20, 21, 23, and 24 at the end of this manual.
Failure to comply with these instructions will result in death or serious injury.

The light curtain is normally mounted in front of the die space and must be located at least the
safety distance from the pinch point. This location ensures that the light curtain can send a
Stop command to the press in time for the press to stop before anyone can reach the pinch
point. Any opening or access to the die space that is not guarded by the light curtain must be
guarded by mechanical barriers.
To determine the Stopping Time of the press, refer to page 6-21. To calculate the correct
safety distance, see page 6-23.

NOTICE
You cannot permanently mount the light curtain until the WPC 2000 is working properly and you
have measured the Stopping Time, set the brake monitor, and calculated the correct safety
distance. However, you will be able to wire the light curtain.

2-22 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

WPC 2000 provides wiring connections for up to two pairs of light curtains (see Table 2-27,
page 2-114). If you wire two sets of light curtains, you must enable them on S101 option
switch 6 (see Table 4-10, page 4-38).

Installing Shadow Light Curtains

Wiring connections for Shadow light curtains are provided in the following wiring diagrams
at the back of the manual:
• Shadow V–Figure 4
• Shadow VI–Figure 14
• Shadow VI Integrated–Figure 15
• Shadow VII–Figures 20 and 21
• Shadow 8–Figures 23 and 24
For Shadow I or Shadow II wiring, contact Wintriss Tech. Support. For complete Shadow
light curtain mounting instructions, see your Shadow user manual.

Setting Jumpers for Shadow VII and Shadow 8 Light Curtains

When you install Shadow VII or Shadow 8 light curtains on your press, you must set jumpers
JP121-JP124 on the WPC 2000 Main Processor board (see Figure 2-14, page 2-28) to the
positions shown in Table 2-3. Wiring diagrams are provided in figures 20 (Shadow VII
control box), 21 (Shadow VII DIN controller), 23 (Shadow 8 optional control), and 24
(Shadow 8 wired directly to WPC 2000) at the back of the manual.

Table 2-3. Shadow VII and Shadow 8 Light Curtain Jumper Settings
Jumper on Main
Processor Board Settings
JP123 PNP
Light Curtain #1
JP124 INT
JP121 PNP
Light Curtain #2
JP122 INT

Installing Non-Shadow Light Curtains

! WARNING
It is your responsibility to ensure that your light curtains are control reliable and intended for use on
a mechanical power press as a primary point-of-operation guard. The manufacturer of your light
curtain should be able to provide the necessary information.
Failure to comply with these instructions could result in death or serious injury.

If you plan to interface a light curtain system other than Shadow with your WPC 2000, please
call Wintriss Tech. Support for instructions. Be ready to provide the following information:
• Light curtain manufacturer
• Light curtain model number

Installation 2-23
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

• WPC model (i.e., WPC 2000)

• WPC 2000 firmware version number (located on A or B microprocessor chip label)
• Wiring diagram from the light curtain manufacturer’s manual
If your WPC 2000 does not have the firmware that allows Foot or One-Hand control and/or
muting of a light curtain on the upstroke, you can connect the light curtain’s dry contact
outputs directly in series with WPC 2000’s E-stop string.

Installing the Resolver

! DANGER
RESOLVER OUT OF SYNCH WITH CRANKSHAFT
Retain the sprockets on the crankshaft and resolver shaft mechanically so they cannot shift or
move out of radial alignment. Be sure that the key on the resolver shaft retains the resolver
sprocket. Use a pin or other method to fix the position of the sprocket on the crankshaft.
Failure to comply with these instructions will result in death or serious injury.

CAUTION
DAMAGE TO RESOLVER
Be sure that the sprocket or gear driving the resolver chain or timing belt is mounted so it is
centered on the crankshaft. If the gear or sprocket is mounted off-center, the resulting loads on
the resolver shaft may cause the unit to fail.
Failure to comply with these instructions could result in property damage.

NOTICE
RAM MUST BE AT TDC BEFORE INSTALLING RESOLVER
The ram must be at top dead center (TDC) before you install the resolver. Use a dial indicator on
the face of the ram if necessary. Set the ram to 0° ±2°.

Because the resolver must provide WPC 2000 with the exact position of the crankshaft at
every degree of the stroke (see Resolver-based Operation, page 1-6), the device must be
driven smoothly at a 1:1 ratio with the crankshaft. Design a method of driving the resolver
directly from the crankshaft, using a chain or timing belt (not a V belt) and sprockets. Use
either an idler sprocket or a spring-loaded resolver base to compensate for slack or stretch.
The drive method you choose must also allow for adjustment of the resolver to its zero
position at top dead center. All sprockets must be keyed or pinned. The resolver shaft has a
standard key. Wintriss stocks a spring-loaded base with a hole pattern to match the resolver.
When designing the drive for the resolver, observe the following precautions:
• Do not use a chain more than three feet in length
• Do not use gears, right-angle joints, or shafts with universal joints, which will develop
either too much backlash or too much play

2-24 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

• Do not try to couple the resolver directly to the crankshaft. Such a placement requires
extreme precision. If the resolver is only slightly off-center, its bearing will be subjected to
side loads well in excess of its rated capacity and will ultimately fail.
• Do not use flexible couplings, which can be inaccurate, or V belts, which can also be
inaccurate and will slip
• Do not use a flexible shaft like a speedometer cable. The resolver will lag the crankshaft
because of the twisting of the shaft on start-up. When the crankshaft stops, the resolver will
turn past the true stopping point and snap backward.

Mounting the Resolver

To mount the resolver, perform the following steps:

NOTICE
It does not matter which direction the resolver turns when the press runs. You adjust for the
direction of rotation when you wire the unit (see Wiring the Resolver, next section).

1. Mount the resolver by bolting it to the press or other platform at the desired location.
2. Make sure the press is at TDC.
3. Rotate the resolver shaft so the keyway is aligned with the arrow on the housing (see
Figure 2-13, page 2-26).
4. Keeping the keyway aligned with the arrow, attach the chain or drive mechanism.

Wiring the Resolver

To wire the resolver, perform the following steps:

1. If the resolver cable is not already connected, locate the cable, plug the molded connector
into the resolver (it only goes one way), and twist the locknut so the connection is tight.
2. Run the resolver cable through conduit from the resolver to one of the knockouts at the
bottom left of the WPC 2000 enclosure.

NOTICE
You can run the resolver and overrun limit switch cables through the same conduit (see
Figure 2-1, page 2-4 for an example). If you do so, make sure not to cut the cable and
wires until both the resolver and the overrun limit switch are installed.

3. Find the resolver terminal block, TB 106, on the WPC 2000 Main Processor board (see
Figure 2-14, page 2-28), and remove the L-shaped connector.
4. Viewing the resolver from the shaft end, determine whether the shaft will turn clockwise
or counterclockwise when the press runs.

Installation 2-25
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

3.62 0.34 (8.6) dia holes

(91.9) 2 places

1.50
(38.1)
3.75
(95.3)
3.00
(76.2) RESOLVER IS AT ZERO WHEN
KEYWAY IS ALIGNED WITH ARROW

9.16
(232.7)

Resolver shown in
zero-degrees position, 3/4” dia. shaft (19.05)
with key perpendicular standard key Electrical connector
to base for cable

2.00
(50.8)
1.06
(26.9)

Dimensions: inches
2.75 1.75 (mm)
(69.9) (44.5)

Figure 2-13. Resolver: Mounting Dimensions

5. Measure and cut the resolver wires so they reach TB 106, then wire them to the L-shaped
connector, referring to Table 2-4, page 2-27, and Figure 1 at the end of the manual. Make
sure you connect the black and yellow wires correctly, based on the direction in which
your resolver will rotate–clockwise or counterclockwise. Refer to Installation Overview,
page 2-4 if you need help wiring the TB 106 connector.

2-26 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Table 2-4. WPC 2000 Resolver (TB 106) Wiring

Pin # Signal Wire Color
104 S4 Return Brown
105 R2 Ground Orange
106 S3 Return Yellow*
107 R1 Drive Red
108 S2 Cosine Green
109 S1 Sine Black*
110 Shield
* Shown for clockwise rotation, facing shaft
For counterclockwise, swap black and yellow wires

NOTICE
CONNECTOR WIRING
Before wiring, place the connector over its base the way it will plug in (it can plug in only
one way) and double-check pin assignments to make sure you wire correctly.

6. Double-check connections when you are finished wiring.

7. Plug the L-shaped connector firmly into its base. It can plug in only one way.
8. To connect resolver wiring between WPC 2000 and SmartPAC 2, refer to page 2-50.

Replacing the Resolver

NOTICE
If the resolver you are replacing is defective, you may not be able to move the ram to TDC. If you
are unable to move the ram, make a note of the angular position of the keyway on the old resolver.
When you install the new resolver, make sure its keyway is in the same position. See step 1,
below.

If you need to replace your resolver, do the following:

1. Perform the Mounting the Resolver and Wiring the Resolver procedures, above.
If you are replacing a defective resolver and were unable to move the ram to TDC, make
sure the keyway on the new resolver is in the same angular position as the keyway on the
resolver being replaced.
2. Check the resolver’s direction of rotation (see procedure above).
3. Rezero the resolver, following the instructions in Zeroing the Resolver, page 2-78.

Installation 2-27
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

103 102 101 100 99 98 97 96 95 94 93 92 91 90 89

+5V B processor
LED TB 105
DS151 Power

Light curtain A
TB 303 TB 302 TB 301 TB 402 TB 401 test mode + 24V I/O
jumper LED Group 7
DSV B DSV A
JP124 DS150 88
TB 403 8 44
87
43
7 86
42
B 6 85
41
F 302

pro-
F 303

Orange
5 84
40
cessor INT 83
4 39
chip 82
U134 EXT 3 38
81
2 37
80
PNP 36
1 79
35
TB104

8
NPN

7
Group 5 Group 6 78

6
34

5
77

4
Light 8 33

3
curtain A 76

2
7 32

ON

1
output type 31
75
jumper 6
74
LEDs

DS 301 JP123 5
30
73

Green
29

8
4 72
LEDs

7
28
DS 402
6
Option 3 71
DS 303
5
27
DS 302 DS 401 switches
4
70
2 26
3
2 S101 69
1 25
ON

68
Aux. E-stop relay board Option TB103
24
67
(Optional) switches 23
S102 Group 3 Group 4
Hi/Lo speed 10 66
jumper DSV/Lockout relay board 9
22
65
JP126 21
(underneath 8 64
20
DSV/Lockout 7 19
63
relay board) Light curtain B 62
RAM 6 18
test mode chip 61

Orange
17
jumper U102
5
60
JP122 4
16
59
15
3 58
Light curtain B 14
57
output type 2 13
jumper PNP 56
1 12
JP121 INT 11
55
Serial Display TB102
NPN EXT
port LEDs cable LEDs
54
10
53
Group 1 Group 2 9
Hi/Lo speed Receive Receive A 52
8
jumper DS1431 DS1371 pro- 6 51
7
JP125 Transmit Transmit cessor 5 50
chip 6
DS1421 DS1381
Green

4 49
U111 5
3 48
4
HI
+5V A processor 2 3
47
LED 46
LO 2
DS149 1 45
1
TB 106 TB 107 TB 108 TB 109 TB101
LED #
Resolver Serial port Display cable Cam outputs

Green Green Orange Green

104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121122123124125126127128129130

Figure 2-14. WPC 2000 Main Processor Board: Location of Important Components

2-28 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Installing the Overrun Limit Switch

! DANGER
MOUNT OVERRUN LIMIT SWITCH SO IT PROVIDES CORRECT TIMING
• Install the overrun limit sensor magnet on a component, such as the crankshaft, that moves
independent of the resolver and whose motion is not affected by the condition of the resolver or
the resolver’s drive mechanism. Safe operation of the press depends on the overrun limit
sensor working correctly when the resolver or its drive mechanism fails.
• Install the overrun limit sensor magnet in the correct angular location according to the
instructions starting on page 2-82.
Failure to comply with these instructions will result in death or serious injury.

The overrun limit sensor, also called the “overrun sensor,” enables WPC 2000 to monitor
operation of the resolver and to stop the press whenever the resolver fails to work properly, as
can happen when the resolver drive chain breaks or slips or when the resolver is broken. The
overrun sensor provides a signal to WPC 2000 at the same resolver angle on every stroke.
Whenever this angle changes, WPC 2000 detects that the resolver is no longer rotating at a 1:1
ratio with the crankshaft and sends an Emergency-stop command to the press, simultaneously
displaying an error code.

Planning Your Overrun Sensor Installation

The overrun sensor consists of a magnetic switch and a magnet. Select a mounting location
for both components that ensures that the magnet moves past the switch once on every stroke
and within 1/8 in. to 3/16 in. (3 mm to 5 mm) of the switch, close enough for the switch to
sense the magnet’s presence. The magnet is mounted to the crankshaft or another component
that rotates identically on every stroke. The switch is hard-mounted to the press or other
surface and remains stationary.

NOTICE
Make sure to position the overrun sensor 1/8 in. to 3/16 in. from the magnet. This gap
specification is different from that of the flywheel speed sensor (see page 2-43).

There must be no connection between the overrun limit sensor and the resolver to ensure that
the overrun sensor continues to operate if the resolver or its drive mechanism fails.
To obtain an adequate overrun signal at high speeds, the magnet should be mounted so that it
can be sensed by the switch for 15° to 25° of the stroke. The interval during which the magnet
is sensed, called the “dwell,” decreases as the diameter of the rotating shaft increases (see
Figure 2-15, page 2-30). Select a shaft whose diameter will allow the sensor to detect the
magnet for the required dwell. A shaft diameter of 4 in. to 6 in. (100 mm to 150 mm) is
optimum.

Installation 2-29
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Actuating
Magnet

11o
o
5” (127 mm) diameter 23 Crankshaft 10” (254 mm) diameter
23o of dwell 11o of dwell

5”

10”
o o
Optimum dwell: 15 to 25

Figure 2-15. Overrun Sensor Magnet Placement: Dwell as a Function of Shaft Diameter

Mounting the Overrun Sensor Switch

NOTICE
INSTALL MAGNET AFTER MOUNTING SWITCH
Install the overrun magnetic switch as instructed in this section. Refer to page 2-82 for instructions
on installing the overrun magnet.

The overrun sensor magnetic switch comes already installed in a bracket. Mount the bracket
and switch at a location past which the magnet will pass on every stroke and within 1/8 in. to
3/16 in. (3 mm to 5 mm) of the magnet, referring to Figure 2-16.

Magnetic switch

Magnet
Mount temporarily
with tape.
Hard mount later.

Press

Diameter
1/8” to 3/16” 4”-6”
Gap between Crankshaft
magnet and Crankshaft
magnetic switch

Figure 2-16. Overrun Sensor Magnetic Switch: Installation Example

2-30 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Place the magnet temporarily on the crankshaft or other mounting surface while you set the
gap between the switch face and the magnet. After tightening down the bracket’s mounting
screws, remove the magnet and put it in a safe place until you mount it permanently.

Wiring the Overrun Sensor Switch

NOTICE
You can run both the resolver wires and the overrun limit sensor cable through the same conduit.
If you do so, wait to cut the cable and wires until both the resolver and the overrun limit sensor are
installed.

Run the cable for the magnetic switch through conduit to the WPC 2000. Connect the wires to
terminal blocks on the WPC 2000 Main Processor board, as shown in Table 2-5 and Figure 1
at the end of the manual.

Table 2-5. Overrun Sensor Switch Wiring Connections

WPC 2000 Main Processor Bd. Signal Wire Color
Pin #
23 +24 Vdc Red
24 Overrun input to WPC 2000 White
25 Ground Black

Wiring WPC 2000 User Inputs

! DANGER
USER INPUTS 1 THROUGH 7 NOT SUITABLE FOR SAFETY USE
DO NOT use inputs 1 through 7 as part of any personnel-protection system. These inputs are not
control reliable.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
USER INPUTS ADD DELAY TO STOPPING TIME
DO NOT connect light curtains or other presence-sensing devices to any user inputs. The cross-
checked input pairs (8/9 and 10/11), though control reliable, are suitable only for applications such
as connecting to safety switches used with interlocking barrier guards.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
MAKE SURE TO WIRE CROSS-CHECKED INPUT PAIR CORRECTLY
Input pairs 8/9 and 10/11 are control reliable only if wired correctly in a pair according to the
instructions in this section.
Failure to comply with these instructions will result in death or serious injury.

Installation 2-31
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

! DANGER
CHECK PRESS TO MAKE SURE IT STOPS WHEN USER INPUT ACTUATES
• WPC 2000 comes from the factory with the inputs bypassed by jumpers. Make sure to remove
the appropriate jumper from the Main Processor board connector when you wire a user input.
Otherwise, WPC 2000 will not receive the signal from the input. Leave all unused inputs
jumpered/bypassed.
• Perform checkout procedures to ensure that the user inputs are wired correctly and that WPC
2000 responds correctly when the user input faults (see page 2-113).
Failure to comply with these instructions will result in death or serious injury.

WPC 2000 user inputs allow you to connect signals from other equipment in order to monitor
auxiliary press functions such as lubrication systems. WPC 2000 provides connections for
two pairs of control-reliable, cross-checked inputs and seven independent inputs that are not
control reliable.
When an input issues a Stop command by opening a normally closed (N/C) relay, a fault code
for the input(s) appears on the SmartPAC 2 display. Stop types for all inputs except cross-
checked user input pair 10/11 are set to E-Stop by default; input pair 10/11 is set to E-Stop/
Lockout. All inputs except input pair 10/11 can be reconfigured by the user on the Press
Control User Interlock Menu in SmartPAC 2 Initialization (see User Interlocks, page 4-24).
Inputs 1-7 can be changed to Top-Stop or E-Stop/Lockout. Cross-checked input pair 8/9 can
be changed to E-stop/Lockout. If you have SmartPAC 2 firmware version 3.32 or higher and
WPC 2000 firmware version 1.70 or higher, an additional stop type, Top-stop/Lockout, is
available for inputs 1-7. Wiring connection and fault code for each input are shown in
Table 2-6, page 2-33.
The cross-checked input pairs generate a fault either when one or both inputs in the pair are
open or when the inputs “disagree” (i.e., one input is open, the other closed) for longer than
100 msec. Cross-checked input pair 10/11 can be used to detect critical safety problems such
as the removal of die receptacle blocks.
E-Stop/Lockout and Top-Stop/Lockout stop types not only issue a Stop command and display
the appropriate fault code but also simultaneously open the Lockout relay and display the
Lockout message on the SmartPAC 2 display. To clear the Lockout message, turn the Stroke
Select switch to OFF and then back to INCH (see Wiring the Lockout Relay, page 2-34 and
Lockout Message, page 7-3).
You can wire the Lockout relay to your motor starter so that ungrounding of a user input or of
either input in an input pair will shut off the motor.
To wire the user inputs, run conductors from the appropriate terminal number on the Main
Processor board to your equipment and then back to either +24 Vdc or ground, as shown in
Table 2-6 and Figure 3 at the end of the manual. (There are several available “Ground” and
“+24 Vdc” terminals on the Main Processor board from which to choose.) Figure 13 at the
back of the manual provides an example of how to wire safety devices to the cross-checked

2-32 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

inputs. After you have wired the inputs you will use, be sure to bypass all the unused inputs
by connecting them to +24 Vdc or ground.

Table 2-6. WPC 2000 User Inputs: Stop Types, Fault Codes, and Wiring Connections
Jumper
User Input Pin Connection Fault Name of Auxiliary
(Interlock) Stop Type * # (Bypass) Code Equipment
User 1 21 +24 Vdc 51
User 2 82 +24 Vdc 52
User 3 71 +24 Vdc 53
User 4 83 Ground 54
User 5 72 Ground 55
User 6 84 Ground 56
User 7 73 Ground 57
User 8 paired 85 Ground
with 9
58, 17
User 9 paired 74 Ground
with 8
User 10 paired 86 Ground
with 11 E-stop/
50, 18
User 11 paired Lockout 18 Ground
with 10

* Stop types for all inputs except input pair 10/11 are set to E-Stop by default; input pair 10/11 is set to E-Stop/Lockout.
All inputs except input pair 10/11 can be reconfigured by the user. If you have SmartPAC 2 firmware version 3.32 or
higher and WPC 2000 firmware version 1.70 or higher, an additional stop type option, Top-stop/Lockout, is available
for user inputs 1-7. To set these inputs to Top-stop/Lockout or to change the stop type setting for any user input, see
page 4-24.

NOTICE
If you do not bypass the unused inputs, WPC 2000 will not work properly.

You can add up to 20 more non-control-reliable user inputs and up to 4 more control-reliable,
cross-checked user inputs to your WPC 2000 by purchasing the Option 1 “daughter” board,
which you install on the WPC 2000 Main Processor board. If you are interested in this
product, contact your local Wintriss representative or call Wintriss Tech. Support. To install,
wire, program, monitor, and troubleshoot the Option 1 board, refer to Appendix J.
You can display the status of all user inputs in SmartPAC Initialization mode. See Input
Status, page 4-44.

Installation 2-33
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Connecting Other Wintriss Products to WPC 2000

You can connect the stop circuits of other Wintriss products to WPC 2000. Before you wire,
complete all WPC 2000 installation, initialization and checkout procedures. Then run the
press in all modes of operation–Inch, Single-stroke, and Continuous (if applicable). Also
make sure that the press has working Top-stop and Emergency-stop circuits. Since WPC
2000 is connected to the press stop circuits, it is extremely important to verify that the press
operates and stops properly before connecting WPC 2000 to other units. Do not forget to
mark on your electrical prints where you wire in WPC 2000.
When the Stopping Time is critical to your operation, as it is with die protection, be sure to
wire as follows. Whenever you have Emergency-stop circuits, wire them between terminals
#67 and #68 or terminals #68 and #69 on the Main Processor board. For Top-stop circuits,
wire them between terminals #79 and #80 or terminals #80 and #81. Refer to Figure 1 at the
end of the manual for specific wiring schematics.
Use customized status code wiring (see Wiring WPC 2000 User Inputs, page 2-31) when the
auxiliary equipment that you are connecting does not have its own self-explanatory displays,
as are available in DiPro 1500 or AutoSet load analyzers.

Installing WPC 2000 Options

Wiring the Lockout Relay
The Lockout relay, which is designed to be wired to critical press functions such as the motor
starter (see Figure 6 at the back of the manual for an example), provides an added safety
feature to WPC 2000. Whenever a serious error condition occurs, the Lockout message will
appear in the SmartPAC 2 display. To clear the Lockout message, turn the Stroke Select
switch to OFF, then back to INCH or one of the other operating modes.
Wire the function you want to be controlled by the Lockout relay to TB 301 on the DSV/
Lockout relay board, which is located in the upper left corner of the WPC 2000 Main
Processor board (see Figure 2-14, page 2-28). Wiring connections are shown in Table 2-7 and
in Figures 16 (Herion DSV), 17 (Ross Serpar DSV), and 22 (Ross DM2 DSV) at the end of
the manual.

Table 2-7. Lockout Relay Wiring Connections (DSV/Lockout Relay Board)

DSV/Lockout Relay Bd.
TB301
Pin # Signal
97 Lockout relay input
98 Lockout relay output
99 Lockout relay output

2-34 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Wiring Auxiliary Outputs

! DANGER
NON-SAFETY OUTPUT USED FOR SAFETY FUNCTIONS
Use Auxiliary outputs 1, 2, and 3 for non-safety functions only, such as convenience in automation.
They cannot protect personnel from a moving hazard.
Failure to comply with these instructions will result in death or serious injury.

WPC 2000 provides three optional Auxiliary outputs that you can use to automate equipment
connected to your clutch/brake control. A summary of wiring connections and change
conditions for these three outputs is provided in Table 2-8. Details about each output are
given following the table. Additional wiring details are provided in Table 2-27, page 2-114
and in Figure 3 at the back of the manual.

Table 2-8. Auxiliary Output Wiring Connections and Change Conditions

Pin #
(WPC 2000 Normal Change
Output Proc. Bd.) State State Change Conditions
Aux. 1 28 On (N/C) Off (or Open) • WPC 2000 fault
• E-stop string open
• Light curtain interruption
• Interrupted Stroke (controlled by
option switch 8–see Table 2-9)
Aux. 2 36 Off (N/O) On (or Closed) • WPC 2000 fault
• Interrupted stroke
• Key switch in Inch and DSV energized
Aux. 3 29 Off (N/O) On (or Closed) • DSV energized

Auxiliary Output 1

Auxiliary 1 is normally closed (N/C), or On. The output opens, or turns Off, when a fault
condition occurs, an E-stop string opens, or a light curtain is interrupted while the press is
running. The output can also be programmed to turn Off during an Interrupted Stroke (see
page 6-38 for an explanation of Interrupted Stroke).
Aux. Output 1 response to an Interrupted Stroke is controlled by option switch 8 on the WPC
2000 Main Processor board. Switch settings are shown in Table 2-9.

Table 2-9. Option Switch 8 Settings for Auxiliary Output 1 State Change
Option Switch 8 Auxiliary Output 1 State Change during Interrupted Stroke
OFF Output turns OFF when an Interrupted Stroke occurs
ON Output remains ON during an Interrupted Stroke unless the Interrupted Stroke
is preceded by a WPC 2000 fault or an Emergency Stop, in which case the
output turns OFF

Installation 2-35
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

When switch 8 is set to OFF, Auxiliary Output 1 opens, or turns Off, at the occurrence of an
Interrupted Stroke. When switch 8 is set to ON, the output turns Off during an Interrupted
Stroke only when there is also a fault or Emergency-stop condition; otherwise, the output
remains On during an Interrupted Stroke. See Auxiliary Output 1 Response to Interrupted
Stroke, page 4-40 for additional details.
The switch 8 ON setting allows the press to be “inched” during an Interrupted Stroke, when
the WPC 2000 is in Two-hand Maintained Single-stroke mode. Normally, in Two-hand
Maintained Single-stroke, the operator must hold down the Run/Inch palm buttons until the
press reaches its Top-stop position in order to avoid another Interrupted Stroke. With switch 8
set to ON, the operator may release the Run/Inch buttons while inching the press to Top-stop
without initiating an Interrupted Stroke.
Auxiliary Output 1 can be wired to a customer-supplied control relay and used to stop
auxiliary equipment such as scrap choppers, conveyors, etc. when one of the conditions
described above causes the press to stop. When a warning beacon is connected to the control
relay, the beacon illuminates when a fault occurs and Aux. Output 1 opens.

Auxiliary Output 2

Auxiliary Output 2 is normally open (N/O), or Off. The output closes to ground, or turns on,
whenever there is an interrupted stroke or fault condition or the press is placed in Inch mode.
Auxiliary Output 2 can be connected to the Setup Mode inputs of DiPro 1500 and AutoSet
1500/1504 Plus. The output is used to disable green sensors in DiPro 1500 or repeatability
setpoints in AutoSet 1500/1504 Plus whenever the press is switched to Inch mode or an
interrupted stroke or fault condition occurs. A customer-supplied output relay can be wired
into this circuit. Refer to the applicable manuals for wiring details.

Auxiliary Output 3

Auxiliary Output 3 is normally open (N/O), or Off. The output closes, or turns On, when the
DSV is energized. When Bar Control is in use (see Operating the Press in Bar Mode,
page 6-52), Aux. Output 3 remains open, or Off, when the DSV is energized.
Auxiliary Output 3 can be wired to the input check circuit of DiPro 1500 or ProCam 1500 and
is used to prevent Loss of Rotation faults on these units when Bar Control is activated.
When WPC 2000 is in Bar Control mode, the DSV is energized to enable the crankshaft to be
turned by hand. Under normal conditions, whenever the DSV is energized, Aux. Output 3
turns On, sending a low-voltage (i.e., 24 Vdc) input check signal to the DiPro 1500 or ProCam
1500.
DiPro/ProCam 1500 uses the input check signal to initiate monitoring of the programmed start
time limit, the interval within which the crankshaft must begin rotating in order to avoid a
Loss of Rotation fault. In Bar Control mode, Aux. Output 3 disables the input check signal,
preventing the 1500 unit from monitoring the start time limit.
Wire Auxiliary Output 3 to the “A” connection of the input check circuit of DiPro 1500 or
ProCam 1500. Wire one of the +24 Vdc outputs on the WPC 2000 Main Processor board
(pins #37 through #42) to the “B” connection of DiPro 1500 or ProCam 1500. If your DiPro

2-36 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

1500 or ProCam 1500 is equipped with a voltage selector switch for the input check circuit,
set it to the 12-60 volt position. Refer to the DiPro 1500 or ProCam 1500 manual for details.

Wiring Operator Mode Outputs

Terminal block TB109 on the WPC 2000 Main Processor board provides outputs to
customer-supplied solid-state relays to allow monitoring of the WPC 2000 operator mode.
Figure 2-17 shows an example of how to wire a relay so that it turns on when WPC 2000 is in
Automatic Single-stroke. Wiring schematics for all operator mode outputs is provided in
Figure 18 at the end of the manual.

WARNING
These operator mode outputs are NOT
control reliable. They can, however, be
used as a convenience to interface
automation.

WPC 2000 Operator Mode Outputs

Solid-State Relay Pin # Pin Designation

121 + 24 VDC (Power)

122 Ground
Output + Input
123 ON in Foot Continuous
124 ON in Two-hand Continuous
Output – Input 125 ON in Automatic Single-stroke
126 ON in Foot Single-stroke
127 ON in One-hand Single-stroke
128 ON in Two-hand Single-stroke
129 ON in all Inch modes and Bar mode
130 ON in OFF mode
Example showing wiring for a
relay to turn on when Automatic
Single-stroke mode is selected.

Figure 2-17. WPC 2000 Operator Mode Outputs: Wiring Example

Installation 2-37
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Wiring a Foot Switch

! DANGER
UNGUARDED HAZARDS
When using a foot switch, ensure that light curtains and other safeguards are properly installed
and operating to protect operators.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
IMPROPER FOOT SWITCH
Ensure that any foot control switch complies with OSHA 1910.217 (b) (7) (x), including protection
from accidental actuation by falling or moving objects or unintentional stepping on the control.
Failure to comply with these instructions will result in death or serious injury.

Foot Switch, an option available from Wintriss, enables the operator to use both hands during
operation of the press as, for example, when manually feeding parts. If you choose to order a
foot switch, you must obtain optional One-hand/Two-hand/Foot firmware from Wintriss and
install a Shadow safety light curtain.
Wire the Foot Switch’s normally closed contact to pin #4 on the WPC 2000 Main Processor
board and the normally open contact to pin #14, then wire both contacts to +24 Vdc, as shown
in Table 2-10 and Figure 3 at the end of the manual.

Table 2-10. Foot Switch Wiring Connections

WPC 2000 Main Processor Bd. Foot Switch
Pin # Contacts
4 N/C input
14 N/O input
+24 Vdc (e.g., #37) Common

Refer to page 4-37 for Foot Switch settings.

2-38 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Installing a One-hand Control

! DANGER
INSTALL SAFEGUARDS TO PREVENT ACCESS TO HAZARDOUS AREA
• Follow all applicable OSHA and ANSI regulations for safeguarding your press system. Point-of-
operation safeguarding is the single most important factor in the prevention of injuries.
• Follow all applicable OSHA and ANSI regulations when installing a one-hand control.
• Ensure that proper safeguarding devices are installed and working properly. Wintriss takes no
responsibility if safeguarding devices are not installed or working correctly.
• DO NOT use WPC 2000 or a one-hand control as a safeguarding device.
• Install and operate WPC 2000 and a one-hand control in accordance with OSHA and ANSI
regulations.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
PREVENT OPERATOR FROM STANDING BETWEEN LIGHT CURTAIN AND HAZARD
Ensure that the operator cannot position himself between the light curtain and the hazardous area.
Use another pair of light curtains or a mechanical barrier at knee to waist height to prevent the
operator or a passerby from being “trapped” between the light curtain and the hazard.
Failure to comply with these instructions will result in death or serious injury.

One-hand Control is a switch available from Wintriss that allows operators to use their free
hand to feed a part while their other hand operates the switch. This option can only be used
with WPC 2000 systems equipped with One-hand and Single-stroke modes, employing a
Shadow light curtain to guard the point of operation, and running One-hand/Two-hand/Foot
firmware.
The One-hand Control is mounted on or near the press and allows the operator to cycle the
press without using the Operator Station. To stroke the press, the operator simply pushes the
button as part of his normal hand motion after loading a part.
The One-hand Control can be used in two different modes. In Normal mode, the press cycles
in Single-stroke whenever you push the One-hand Control button. In “Light Curtain Break”
mode, the press cycles only when you push the One-hand Control button within eight seconds
after removing your hand(s) from the light curtain. If the button is pushed after this interval
expires, the press does not cycle.
Light Curtain Break mode prevents inadvertent operation of the press when an operator is
loading or unloading parts.
The mode used for One-hand Control is determined by the setting on option switch 3 (see
page 4-36). When switch 3 is set to OPEN, One-hand Control operates in Normal mode.
When switch 3 is set to CLOSED, One-hand Control operates in Light Curtain Break mode.

Installation 2-39
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Mounting a One-hand Control

! DANGER
DO NOT MOUNT OPERATOR CONTROL TOO CLOSE TO HAZARD
Mount the One-hand Control outside the area protected by the light curtain. DO NOT mount the
One-hand Control between the light curtain and the point of operation.
Failure to comply with these instructions will result in death or serious injury.

To mount the One-hand Control, perform the following steps, referring to Figure 2-18 and
Figure 2-19, page 2-41 for mounting dimensions:

Figure 2-18. One-hand Control Switch: Mounting Dimensions

2-40 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Figure 2-19. One-hand Control Switch Base: Mounting Dimensions

1. Shut off power to the press and to WPC 2000.

2. Choose a mounting location on or near the press convenient to the operator. The
One-hand Control should be mounted so the operator can reach it as part of normal hand
movement after loading a part. An adjustable bracket may be necessary.
3. Mount the One-hand Control, using the tapped holes on the bottom of its metal enclosure.

Wiring a One-hand Control to WPC 2000

! 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.

To wire One-hand Control, you need to make connections to both the Operator Station and to
the WPC 2000 Main Processor board. To do so, perform the following steps:
1. Turn off power to the press and to the WPC 2000.

Installation 2-41
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

2. Loosen the clips at the bottom of the front panel of the Operator Station. Swing the front
panel up and support it so you can work inside the box. (The cover will stay up if you
slide it slightly to the left or right.)
3. Knock out a hole in the bottom of the Operator Station near the existing conduit from the
WPC 2000 control enclosure.
4. Using the conduit hole provided in the base of the One-hand Control, run conduit and
wiring to the Operator Station, referring to Figure 2-20 for terminal locations on the
bottom of the One-hand Control.

Figure 2-20. Wiring Connections in One-hand Control Switch (Switch Cover, Bottom View)

5. Measure wires to fit before cutting, then make the appropriate wiring connections,
referring to Table 2-11, below, and Figure 8 at the end of the manual.

Table 2-11. One-hand Control Wiring Connections

WPC 2000 Main Processor Bd. and
One-hand Control Operation Station Connections
Terminal # * Pin# Signal
11 1 Palm switch A N/C input +
12 Blue wire in Operator Station cable
13 3 One-hand A input +
14 Blue wire in Operator Station cable
* Refer to Figure 2-20, above

6. Fasten the switch cover onto the base with the screws provided.
7. Tighten all conduit connections that may have been loosened during installation.
8. Close and latch the cover of the Operator Station and WPC 2000.
9. Make sure that you have run all your ground wires. Do not use conduit as ground.

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Wiring a Keylock Switch to Prevent Changes to WPC 2000 Settings

You can use a keylock switch (not supplied by Wintriss) to provide additional security that
supersedes the Run mode lockout provided in SmartPAC 2. Refer to Additional Security,
page 4-52 for more information.
Wire your keylock switch between ground and SmartPAC 2 terminal #251 on TB107.
• Switch CLOSED (grounded): prevents changes to any WPC 2000 settings in Program and
Run modes
• Switch OPEN (not grounded): Normal operation of Program and Run modes.

Installing Flywheel Speed Sensor

! WARNING
INJURY FROM MAGNETS THAT DETACH
Mount the magnets with the brass screws provided. If you mount them with plastic screws or
adhesive, the attachment could fail and the magnets become dangerous projectiles, especially on
high-speed presses.
Failure to comply with these instructions could result in death or serious injury.

You can monitor the speed of the press’s flywheel by installing a Latching Magnetic Cam
Switch (LMCS), an option available from Wintriss. The LMCS consists of the following
parts:
• A sensor mounted on a bracket with wiring for connection to the WPC 2000 Main
Processor board
• Two magnets, one red, the other blue, for attachment to the flywheel
• Two brass screws, one for mounting each magnet
To install the LMCS, do the following:
1. Select a mounting location that allows the sensor to detect the magnets as they rotate on
the flywheel. The magnets should be mounted approximately 180° apart to ensure that the
LMCS transitions from Off to On once per revolution.
2. Fabricate a bracket to position the LMCS 3/8 in. to 1/2 in. from the face of the magnets. If
possible, make the bracket adjustable.

NOTICE
Make sure to position the LMCS sensor 3/8 in. to 1/2 in. from the magnets. This gap
specification is different from that of the overrun limit switch (see page 2-29).

3. Install the LMCS as shown in Figure 2-21, page 2-44.

Position the magnets so they are approximately 180° apart. Magnets should be installed
plastic side up with a non-ferrous metal screw. A ferrous screw may cause false signals.
A brass screw (6-32) is supplied with each magnet. Use a No. 36 drill and a 6-32 tap.

Installation 2-43
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

NOTICE
Be sure to position the red and blue magnets on the flywheel approximately 180° apart.

Figure 2-21. Installing the LMCS and Magnets

4. Run the cable from the LMCS sensor through flexible, liquid-tight conduit to the WPC
2000 enclosure. The enclosure is rated NEMA 12 (protected against dust and oil). You
must use conduit rated NEMA 12 and make proper conduit connections to ensure NEMA
12 protection.
5. Wire the LMCS to the WPC 2000 Main Processor board as shown in Table 2-12.

Table 2-12. Flywheel Speed Sensor Wiring Connections

WPC 2000 Main Processor Bd. LMCS Wire Color
Pin #
22 White
23 Red
25 Black

6. Double-check wiring connections.

Mounting and Wiring the Bar Control Enclosure

Mount the Bar Control enclosure in a location that is convenient to the operator while he is
releasing the machine’s brake and barring the press. Make sure that the operator will not
block a light curtain while pressing the Bar control Operate button. Refer to Figure 2-22,
page 2-45 for mounting dimensions.
To wire the Bar Control, connect the Bar selector switch input to pin #6 on the WPC 2000
Main Processor board and the Bar actuator input to pin #16, as shown in Table 2-13,
page 2-45 and Figure 3 at the end of the manual.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

7.49 4.60
(190.2) (116.8)
6.70
(170.2) 3.24
(82.3)
6.23
(158.2) 3.13
(79.5)

BAR CONTROL
OFF ON
(50.8)
2.00
(111.8)
4.40

SELECT OPERATE
(127.5)
5.02

DATA INSTRUMENTS
Wintriss Controls Group
0.312
(7.9)
4 places
Dimensions: inches
(mm)

Figure 2-22. Bar Control Enclosure: Mounting Dimensions

Table 2-13. Bar Control Wiring Connections

WPC 2000 Main Processor Bd. Bar Control Contacts
Pin #
16 Bar actuator input
6 Bar selector switch input
+24 Vdc (e.g., #37) Common

Installation 2-45
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Wiring Automatic Single-stroke

! DANGER
PRESS STARTING UNEXPECTEDLY
• Ensure that light curtains and other safeguards are properly installed and operating to protect
operators when using Automatic Single-stroke. Since the external trigger starts the stroke, a
stroke can occur unexpectedly.
• Ensure that guarding is properly installed to prevent access to the machine over, under, or
around any guarding device.
Failure to comply with these instructions will result in death or serious injury.

Automatic Single-stroke is an operating mode that enables the operator to automate a manual
press using a feeding device or robot. To wire the Automatic Single-stroke actuating
mechanism, refer to Table 2-14 and Figure 3 at the back of the manual.

Table 2-14. Automatic Single-stroke Wiring Connections

WPC 2000 Main Processor Bd. Foot Switch
Pin # Contacts
15 N/C input
5 N/O input
+24 Vdc (e.g., #37) Common

Though an SPDT contact is shown in Figure 3, you can also use solid state switches
(proximity switches, for example) or outputs from a programmable logic controller (PLC).
To make sure that the contacts are clear and reliable, the switch or relay should be new and
unused.
You set the Prior Act time for Automatic Single-stroke with option switch 5 (see page 4-38).
To operate the press in this operating mode, refer to page 6-48.

Wiring Automatic Continuous On-demand

! DANGER
PRESS STARTING UNEXPECTEDLY
• Ensure that light curtains and other safeguards are properly installed and operating to protect
operators when using Automatic Continuous On-demand mode, in which a stroke can occur
unexpectedly.
• Ensure that guarding is properly installed to prevent access to the machine over, under, or
around any guarding device.
Failure to comply with these instructions will result in death or serious injury.

Contact Wintriss Tech. Support for information on using this operating mode.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Installing SmartPAC 2
Mounting the SmartPAC 2 Control Enclosure

NOTICE
If your SmartPAC 2 is a panel mount version, go to the next section, page 2-48, for mounting
instructions.

NOTICE
PLACE SMARTPAC 2 AT A CONVENIENT HEIGHT
SmartPAC 2 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 2-23.

14.2 REF
(360)
10.00
(254.0)
1.00
(25.4)
TYP

SmartPAC 2
F1
POWER F2
F3
BRAKE
WARNING
F4
13.25
(336.6) 12.51 F5
(317.8)
F6
F7
F8

INCH
SINGLE
STROKE
CONT
1 2 3 PROG RUN
ENTER
OFF
4 5 6
HELP

7 8 9 RESET

CLEAR
0 .

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 2-23. SmartPAC 2 Mounting Dimensions: Enclosure

Installation 2-47
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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.
3. Go to Wiring between WPC 2000 and SmartPAC 2, page 2-50 to start wiring your
SmartPAC 2.

Installing SmartPAC 2 as a Panel Mount

If you have received the panel-mount configuration of SmartPAC 2, 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 for mounting SmartPAC 2.
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 2-24, page 2-49 for mounting and “cutout” dimensions.
3. Mount SmartPAC 2 in your enclosure, accessing wiring connections from the back.
4. Go to Wiring between WPC 2000 and SmartPAC 2, page 2-50 to start wiring your
SmartPAC 2.

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12.30 NOTE:
(312.4) SmartPAC and SmartPAC 2
both use the same size cutout:
9.5 x 11 inches. The top 9 holes
are in the same location.
SmartPAC 2
If you are replacing a SmartPAC
F1 with a SmartPAC 2, drill three
POWER F2 additional holes at the locations
shown for the bottom three holes.
F3
BRAKE
WARNING
F4 Allow 6 inches (153 mm)
F5 minimum clearance behind
the panel
11.30 F6
(287.0)
F7
F8
Dimensions:
INCH
SINGLE
STROKE
CONT
1 2 3 PROG RUN Inches (mm)
ENTER

4 5 6
OFF

HELP

7 8 9 RESET

CLEAR
0 .
Panel Cutout

10.65
0.35 (270.5) 0.35
(8.9) 5.50 (8.9)
TYP (139.7) TYP
0.35
0.35
(8.9)
(8.9)
TYP
TYP

4.50
(114.3)

9.00
(228.6)

8.65
(105.4)

10.35
(261.6)

11.00
(279.4)

Figure 2-24. SmartPAC 2 Mounting and Cutout Dimensions: Panel Mount

Installation 2-49
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Wiring between WPC 2000 and SmartPAC 2

This section shows you how to make the following wiring connections between WPC 2000
and SmartPAC 2:
• WPC 2000 resolver wiring
• Communications wiring
• AC wiring
• Stop circuit and input check circuit wiring
As shown in Figure 2-1, page 2-4, you run the resolver and communications wiring through
one conduit (for low-voltage connections), AC, stop circuit, and input check circuit wiring
through another conduit (for high-voltage connections). Refer to Figure 2-25, page 2-51 and
Figure 1 at the end of the manual when making wiring connections.

Connecting the Resolver Wiring

NOTICE
Make sure you have already wired the resolver directly to the WPC 2000 (see page 2-25). In the
following procedure, you will wire in parallel between the “resolver” terminals on TB106 on the
WPC 2000 Main Processor board and the “resolver” terminals on TB101 on the SmartPAC 2
board. This wiring scheme makes WPC 2000 the “master,” SmartPAC 2 the “slave.”

To wire the resolver from WPC 2000 to SmartPAC 2, perform the following steps, referring
to Table 2-15, page 2-51, Figure 2-25, page 2-51, and Figure 1 at the end of the manual.
1. Make sure that the resolver is connected directly to WPC 2000.
2. Find one of the two 6-conductor shielded cables without connector, and run it through
1/2 in. flexible, liquid-tight conduit from the bottom right of the WPC 2000 enclosure to
the bottom left of the SmartPAC 2 enclosure (see Figure 2-1, page 2-4). Both WPC 2000
and SmartPAC 2 are rated NEMA 12 (protected against dust and oil). You must use
conduit of the same rating and make proper connections to ensure NEMA 12 protection.
3. Remove the resolver connector, TB106, from the WPC 2000 Main Processor board (it is
already wired to the resolver), and connect wiring from the 6-conductor cable to terminals
104 through 110, matching brown wire to brown wire, orange to orange, yellow to yellow,
and so forth (see Table 2-4, page 2-27). Then plug the connector back into TB106.

NOTICE
WIRE AND PLUG IN CONNECTOR CORRECTLY
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.

4. Remove the resolver connector, TB101, from the SmartPAC 2 board (see Figure 2-25) and
connect wiring from the 6-conductor cable to terminals 212 through 218, as shown in
Table 2-15. Plug the connector back into TB101 when you are done.

2-50 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

5. Double-check connections when you are finished wiring.

6. Locate jumper JP101 on the SmartPAC 2 board (see Figure 2-25), and move it to the
“Slave” position.

Table 2-15. SmartPAC 2 Resolver (TB101) Wiring

Pin # Signal Wire Color
212 Shield Shield
213 S1 Black*
214 S2 Green
215 R1 Red
216 S3 Yellow*
217 R2 Orange
218 S4 Brown
* Shown for clockwise rotation, facing shaft.
For counterclockwise, swap black and yellow wires.

INPUT CHECK
FUSE
ProCam DiPro E-STOP
TB102 FUSE
1
A B
TOP STOP
POWER FUSE
LEDS F101 F102 F103

TOP
STOP
JP102 LOW LED

K101 K102
HIGH TOP
SPEED STOP
COMPACT RELAY
FLASH E-STOP
ACCESS LED RELAYS
TB105
INPUT
ETHERNET LEDS JP101 CHECK
LINK MASTER SWITCH S101 TX
ACTIVITY BATTERY RX
+ SLAVE
POSITION
SENSOR E-STOP
LEDS TX
LED RX
ETHERNET INPUT
CHECK
LED
TB101 RESOLVER 1

1 1
TB106
AUX I/O TB107

USB PORT TX
LEDS ZERO RX
USB CAM
LED

PS/2 TX
RX

TB104 TB103
PACNET SFI 1
SPECIAL 1 MODULE
1

Figure 2-25. SmartPAC 2 Board: Location of Components

Installation 2-51
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Connecting Communications Wiring

To connect communications wiring between SmartPAC 2 and WPC 2000, perform the
following steps, referring to Table 2-16, below, and to Figure 1 at the end of the manual:
1. Find the other 6-conductor shielded cable, and run it through the same conduit as you ran
the resolver wiring in the previous procedure (see step 2, page 2-50).
2. Remove the TB105 connector from the SmartPAC 2 board (see Figure 2-25, page 2-51 for
location), and connect wiring from the 6-conductor cable as shown in Table 2-16. Plug
the connector back into TB105 when you are done.
3. Remove the TB107 connector from the WPC 2000 Main Processor board (see
Figure 2-14, page 2-28 for location), and connect wiring from the 6-conductor cable as
shown in Table 2-16. Plug the connector back into TB107 when you are done.
4. Double-check connections when you are finished wiring.

Table 2-16. Communications Wiring: SmartPAC 2 to WPC 2000

Pin # on TB105 Pin # on TB107
SmartPAC 2 Wire Color * WPC 2000
Shield ** Shield Shield **
326 (Ground) Black 111 (Ground)
327 (+RxD6) Red 115 (+TxD)
328 (-RxD6) Green 114 (-TxD)
329 (+TxD6) Orange 113 (+RxD)
330 (-TxD6) Yellow 112 (-RxD)
* Cut off unused brown wire.
** Terminate to ground stud nearest entry to enclosure

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, Top-stop, and Input Check 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 from the top left of WPC 2000 to the top
right of SmartPAC 2. Then, to wire the AC input terminal block, follow these steps:

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

1. Find the AC terminal block at the top right corner of the back wall of the enclosure (see
Figure 2-26).

Ground

L2 L1
(Neutral) (High)

Terminal block
Setscrew
terminal

Figure 2-26. Wiring AC to Terminal Block, Inside Enclosure, Top Right

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 PC board.
2. Determine how you will bring wiring for your 115 Vac power source (or 230V source, if
applicable) from WPC 2000 to the SmartPAC 2. Run a 3-conductor shielded cable (you
must supply your own cable) through flexible, liquid-tight conduit from the top left of the
WPC 2000 enclosure to the top right of the SmartPAC 2 enclosure.
AC wiring 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 2-26. 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.

Installation 2-53
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Connecting Stop Circuits and Input Check Circuit

To connect stop circuit and input check circuit wiring between WPC 2000 and SmartPAC 2,
perform the following steps:
1. Supplying your own multi-conductor cable (six wires minimum–two for the
Emergency-stop circuit, two for the Top-stop circuit, and two for the Input Check circuit),
run the cable through the same flexible, liquid-tight conduit as you ran AC wiring (see
step 2, page 2-53) from the bottom right of the WPC 2000 enclosure to the bottom left of
the SmartPAC 2 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 NEMA 12 protection.
2. Locate connector TB102 on the SmartPAC 2 board (see Figure 2-25, page 2-51), and
unplug it from its socket. Connect the wires for stop and input check circuits to TB102 pin
locations, as shown in Table 2-17, below, and Figure 1 at the end of the manual. Plug the
connector back into TB102 when you are done.

Table 2-17. Stop and Input Check Circuit Wiring Connections

SmartPAC 2 WPC 2000
TB102 Pin # Circuit Pin #
205 Input check A 41 (TB104)
206 Input check B 29 (TB103)
207 E-stop 68 (TB103)
208 E-stop 67 (TB103)
209 Top-stop 80 (TB104)
210 Top-stop 79 (TB104)

3. Locate connectors TB103 and TB104 on the WPC 2000 Main Processor board (see
Figure 2-14, page 2-28), and unplug them from their sockets. Connect the wires for stop
and input check circuits to the appropriate pin numbers on TB103 and TB104, as shown in
Table 2-17 and Figure 1. Plug the connectors back into TB103 and TB104 when you are
done.
4. Double-check connections to make sure that you did not wire the connectors backwards
(see Connecting Wires to Terminal Block Connectors, page 2-5).
5. Make all the necessary conduit connections to ensure NEMA 12 protection.

NOTICE
Be sure to number all wires in a way consistent with your press’s electrical prints.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Setting the Input Check Voltage Switch

When the input check circuit is wired as shown in Table 2-17, page 2-54, do the following:
1. Find the input check voltage switch, S101, on the SmartPAC 2 board (see Figure 2-25,
page 2-51). It is located on the right side of the board just beneath the E-stop relays.
2. Place S101 in the Down position.
When the input check circuit is wired directly in parallel with the coil of the dual safety valve,
do the following:
1. For a coil voltage of 60-250V, the switch should be placed in the Up position, the factory
setting; for 12-60V coil voltage, place the switch in the Down position.

S101
Push switch up
for 60-250V

Push switch down

for 12-60V

Figure 2-27. Input Check Switch (S101)

NOTICE
HOW THE INPUT CHECK CIRCUIT DETECTS RESOLVER CHAIN BREAKAGE
When the dual safety valve relay is energized by the press control to start the press,
voltage is produced in the input check circuit. This signals SmartPAC 2 to initiate a stroke
at the press. If SmartPAC 2 gets no signal from the resolver within the specified start time
limit (resolver not turning), SmartPAC 2 opens the Emergency-stop circuit and a “loss of
rotation” fault message is displayed on the LCD. The fault indicates that the resolver belt
or chain is broken or so loose that the resolver shaft cannot move. Other possible reasons
for the fault are low air pressure to the clutch or a bad clutch.

Connecting SmartPAC 2 to a Network

Before you can connect SmartPAC 2 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 board (see
Figure 2-25, page 2-51).

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 4-60.

Installation 2-55
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Installing SmartPAC 2 Options

Adding or Upgrading DiProPAC or 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 DIPROPAC AND/OR PROCAMPAC BOARDS IN CORRECT LOCATIONS
Install these boards in the locations shown in Figure 2-28, page 2-57. If you install a board in the
wrong location, SmartPAC 2 will not recognize that the option is installed.
Eight-, 16-, and 32-channel configurations of the same option are interchangeable. When a board
is installed in the correct location, SmartPAC 2 recognizes whether it is an 8-, 16-, or 32-channel
version of DiProPAC or an 8- or 16-channel version of ProCamPAC.

NOTICE
DIPROPAC 32 MAY REQUIRE FIRMWARE UPGRADE
The DiProPAC 32 module requires that you be running SmartPAC 2 firmware version 4.42 or
higher. If your current SmartPAC 2 firmware version is lower than 4.42, you must upgrade your
firmware before installing the DiProPAC 32 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 page 4-1),
and selecting the CLEAR TABLES item (see page 4-61). 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 and/or programmable limit
switch capabilities to a basic SmartPAC 2 or upgrade your existing die protection and

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

programmable limit switch capabilities. DiProPAC is available as an 8-sensor, 16-sensor, or

32-sensor board. You can obtain the ProCamPAC board in 8-cam or 16-cam versions.
Wiring instructions for the DiProPAC board are provided starting on page 2-61. Wiring for
the ProCamPAC board is documented starting on page 2-63.

Replacing an Existing Board

To replace an existing DiProPAC or ProCamPAC board, do the following:

1. Turn off power to the SmartPAC 2.
2. On the SmartPAC 2 board, locate the board that you wish to replace (see Figure 2-28).
+3.3V
+12V

TB102
1
A B

E STOP

T STOP
260 261 262 263 264 265 266 267 268 269 270 282 283 284 285 286 287 288 289 290 291

POWER
LEDS 292 293 294 295 296 297 298 299 300 301
F101 F102 F103
+5V
-12V

JP102
ProCamPAC 16
ProCamPAC 16 DiProPAC
DiProPAC3216 K101 K102

302 303 304 305 306

board
board board
board
COMPACT
FLASH
ACCESS LED
TB105

WPC
ETHERNET LEDS JP101
LINK S101 TX
ACTIVITY RX

60-250

K101
K102
180 181 182 183 184 185 186 187 188 189

SPARE 1
TX

POS SEN 12-60

271 272 273 274 275 276 277 278 279 280 281

190 191 192 193 194 195 196 197 198 199 RX
ETHERNET

LOCKOUT
IN/SETUP
REM RST

OP STA 2
OP STA 1
Z CAM
+15V

GND

GND
TB101 RESOLVER 1

1 1
TB106
AUX I/O TB107
WRITE
READ

SPARE 2
TX
RX
USB

TX
SPARE 3

RX
RX

RX

RX

RX
TX

TX

TX

TX

TB104 TB103
SPECIAL PACNET 1 SFI MODULE 1

Figure 2-28. DiProPAC and ProCamPAC Boards Installed on SmartPAC 2 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.

Installation 2-57
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

3. Making sure you are grounded, remove the connector(s) attached to the board, one
connector for an 8-sensor or 8-cam unit, two connectors for a 16-sensor or 16-cam unit
(see Figure 2-29 and Figure 2-30).

1 1 1

282 283 284 285 286 287 288 289 290 291 282 283 284 285 286 287 288 289 290 291 282 283 284 285 286 287 288 289 290 291

TB554 TB554 TB554

Wiring connector for
sensor inputs 1-8
(also DiProPAC 16 and 32) 292 293 294 295 296 297 298 299 300 301 292 293 294 295 296 297 298 299 300 301

LEDs for TB553 TB553 TB553

sensor inputs 1-8 Wiring connector for
(also DiProPAC 16 and 32) sensor inputs 9-16
302 303 304 305 306

302 303 304 305 306

302 303 304 305 306

(also DiProPAC 32)
LEDs for
sensor inputs 17-24
Wiring connector for LEDs for
auxiliary outputs sensor inputs 9-16
(also DiProPAC 16 and 32) (also DiProPAC 32) LEDs for
1 1
sensor inputs 25-32 1

1
Wiring connector for
sensor inputs 17-24
180 181 182 183 184 185 186 187 188 189

TB555
Wiring connector for
sensor inputs 25-32
190 191 192 193 194 195 196 197 198 199

DiProPAC 8 DiProPAC 16 DiProPAC 32

Figure 2-29. DiProPAC Boards (8-, 16-, and 32-Sensor): Location of Components

1 1

260 261 262 263 264 265 266 267 268 269 270 260 261 262 263 264 265 266 267 268 269 270

TB401 TB451

Cam channel 1-8 Cam channel 1-8

wiring connections wiring connections

Cam channel 9-16

wiring connections

TB452

271 272 273 274 275 276 277 278 279 280 281

ProCamPAC 8 ProCamPAC 16

Figure 2-30. ProCamPAC Boards (8- and 16-Channel): Location of Components

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

If you are replacing a DiProPAC board, the connector(s) go to the DiPro Sensor Interface.
If you are replacing a ProCamPAC board, the connector(s) go to the ProCam 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 board and out of its
connector.
7. Making sure that you are still grounded, install the new board by plugging it into the
appropriate connector, J111 or J112 (see Figure 2-25, page 2-51). Connectors are keyed,
so you can only plug in the boards 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.
If you are upgrading from an 8- to a 16-sensor DiProPAC, from a 16- to a 32-sensor
DiProPAC, or from an 8- to a 16-channel ProCamPAC, make sure you plug the
connector(s) into the correct terminal block(s). Terminal block assignments for the
different boards are as follows (see Figure 2-29 and Figure 2-30):
• 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
• ProCamPAC 8: Cam channels 1-8 to TB401
• ProCamPAC 16: Cam channels 1-8 to TB451, channels 9-16 to TB452
10. If you have installed a board with an additional connector (i.e., a 16-sensor or 16-channel
board in place of an 8-sensor or 8-channel board, or a 32-sensor board in place of a 16-
sensor board), wire that connector or those connectors to the appropriate component. For
the DiProPAC board, wire the connector to the DiPro Sensor Interface, following the
instructions starting on page 2-61. For the ProCamPAC board, wire the connector to the
ProCam Output assembly, following the procedure starting on page 2-63.
11. Verify that you have installed the board(s) properly by performing the Verifying
Installation of DiProPAC and ProCamPAC procedure, page 2-74. You need to complete
this procedure before you can use SmartPAC 2.

Installing a New Board

To install a new DiProPAC or ProCamPAC board, do the following:

1. On the SmartPAC 2 board, locate the connector in which the new board should be
installed (see Figure 2-28).

Installation 2-59
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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
appropriate connector, J111 or J112 (see Figure 2-25, page 2-51). Connectors are keyed,
so you can only plug in the boards 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, one connector for an 8-sensor or 8-cam unit, two
connectors for a 16-sensor or 16-cam unit, four connectors for a 32-sensor unit. Terminal
block assignments for the different boards are as follows (see Figure 2-29 and
Figure 2-30):
• 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
• ProCamPAC 8: Cam channels 1-8 to TB401
• ProCamPAC 16: Cam channels 1-8 to TB451, channels 9-16 to TB452
5. Wire the connector(s) to the appropriate component(s). For the DiProPAC board, wire the
connector(s) to the DiPro Sensor Interface, following the instructions starting on
page 2-61. For the ProCamPAC board, wire the connector(s) to the ProCam Output
assembly, following the procedure starting on page 2-63.
6. Plug the connector(s) back into their sockets on the board.
7. Verify that you have installed the board(s) properly by performing the Verifying
Installation of DiProPAC and ProCamPAC procedure, page 2-74. You need to complete
this procedure before you can use SmartPAC 2.

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Connecting DiPro Sensor Interface to SmartPAC 2

To connect your DiPro die protection sensors through the DiPro Sensor Interface (DSI) 2,
refer to Table 2-18 (below) to wire sensors 1-8, Table 2-19, page 2-62 to wire sensors 9-16,
Table 2-20, page 2-62 to wire sensors 17-24, and Table 2-21, page 2-63 to wire sensors 25-32.
Wiring diagrams (Figure 9 for sensors 1-16, Figure 10 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 2-18. DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 1-8
Wire color* 1st DSI 2 (TB2) DiProPAC (TB554)
Pin # Pin Designation 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
Black 9 GND 291 GND
10 GND No connection
11 +5 VDC No connection
Shield Terminate drain wire to ground Terminate drain wire to ground
stud stud
* Your colors may be different

Installation 2-61
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Table 2-19. DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 9-16
Wire color* 2nd DSI 2 (TB2) DiProPAC (TB554)
Pin # Pin Designation 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
Black 9 GND 301 GND
10 GND No connection
11 +5 VDC No connection
Shield Terminate drain wire to ground Terminate drain wire to ground
stud stud
* Your colors may be different.

Table 2-20. DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 17-24
Wire color* 3rd DSI 2 (TB2) DiProPAC (TB555)
Pin # Pin Designation 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
Black 9 GND 189 GND
10 GND No connection
11 +5 VDC No connection
Shield Terminate drain wire to ground Terminate drain wire to ground
stud stud
* Your colors may be different

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Table 2-21. DiPro Sensor Interface (DSI) 2 to SmartPAC 2 Wiring, Sensors 25-32
Wire color* 4th DSI 2 (TB2) DiProPAC (TB555)
Pin # Pin Designation 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
Black 9 GND 199 GND
10 GND No connection
11 +5 VDC No connection
Shield Terminate drain wire to ground Terminate drain wire to ground
stud 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’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 clutch/brake control or 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.

If you have purchased the ProCamPAC option with SmartPAC 2, you have received a
separate output assembly for wiring up to sixteen cam channels to your equipment. The
assembly contains the relays that open and close at the angles you set in SmartPAC 2, turning

Installation 2-63
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

your equipment on and off. 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 control, follow the instructions below. These instructions may be used with
either the 8- or 16-channel ProCamPAC board. Refer to Table 2-22 and Table 2-23,
page 2-67 for wiring connections. A wiring diagram is provided in Figure 11 at the end of the
manual.
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 2-31, page 2-65.
3. Select the relays to be used with each channel. Relays should already be plugged into the
Cam Outputs board (see Figure 2-32, page 2-66), 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 2-32.
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.
4. 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.
5. Locate the 12-conductor cable(s) for wiring the ProCamPAC board (see Figure 2-30,
page 2-58 for layouts of 8- and 16-channel boards) to terminal block TB301 inside the
ProCamPAC Output enclosure. If you are wiring an 8-channel ProCamPAC, one cable is
supplied (for channels 1-8). If you are wiring a 16-channel board, two cables are supplied,
one for channels 1 through 8, the other for channels 9 through 16.
6. Remove the appropriate connector(s) from its socket on the ProCamPAC board (TB401
for an 8-channel ProCamPAC, TB451 and TB452 for a 16-channel ProCamPAC).
Connect wires from the 12-conductor cable(s) to the pin locations on the appropriate
terminal blocks, as shown in Table 2-22, page 2-67 (for the 8-channel option) or
Table 2-22 and Table 2-23 (for the 16-channel option). See also Figure 11 at the end of
the manual.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Cam output 6.00

enclosure (152.4) 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)
TB303 TB302

NOTE:
For channels 5-8, CHAN 8 CHAN 7 CHAN 6 CHAN 5 CHAN 4 CHAN 3 CHAN 2 CHAN 1

plug in standard or
solid state, but not both Terminals for connecting wires to equipment Clearance hole
for #6 screw
(4 places)

Figure 2-31. ProCamPAC Output Assembly

Installation 2-65
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Connection to
press control TB301

DS301

Solid State Relays

Channels 5-8
LEDs for channels
Use only one relay
(mechanical or solid state)
for each channel

Relay 6 Relay 5 Relay 4 Relay 3 Relay 2 Relay 1

K311 K309 K307 K305 K304 K303 K302 K301

Mechanical
Relays

Fuses

TB303 TB302

CHAN 8 CHAN 7 CHAN 6 CHAN 5 CHAN 4 CHAN 3 CHAN 2 CHAN 1

Counter Cam 4 Cam 3 Cam 2 Cam 1
on - 200o
off - 250 o Connect to loads
to be controlled

Figure 2-32. Cam Outputs Board

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Table 2-22. ProCamPAC to Cam Output Assembly TB301 Wiring, Cams 1-8
8-cam: ProCamPAC TB401 (cams 1-8) 1st Cam Output Board
Wire 16-cam: ProCamPAC TB451 (cams 1-8) TB301 (Pin #)
(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 2-23. ProCamPAC to Cam Output Assembly TB301 Wiring, Cams 9-16
Wire 16-cam: ProCamPAC TB452 (9-16) 2nd Cam Output Board
(Pin #) TB301 (Pin #)
CHAS (1)
White Relay Pwr (281) A (3)*
Black GND (280) B (2)*
Red +5 (279) +5 Vdc (4)
Tan Ch 16 (278) Ch 8 (5)
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

7. Plug the connector(s) back into its socket.

8. Run the cable(s) through conduit to TB301 in the ProCamPAC Output enclosure, using
the knockouts directly above the connector.

Installation 2-67
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

9. Remove the TB301 connector from its socket, and connect wires from the 12-conductor
cable(s) as shown in Table 2-22 (for 8-channel ProCamPAC) or Table 2-22 and
Table 2-23 (for 16-channel ProCamPAC). A wire from CHAS to a lug on the
ProCamPAC Output enclosure should already be connected (unless you bought the board
assembly only).
10. Plug the connector(s) back into its socket.
11. To connect the relays to your equipment, use connectors TB302 and TB303 (see
Figure 2-33).

TB303 TB302

CHAN 8 CHAN 7 CHAN 6 CHAN 5 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 N/C C N/O N/C C N/O N/C C N/O N/C C N/O

Figure 2-33. 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. 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 2-24.)

Table 2-24. Connections to Relays

Module How To Connect Type
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.

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12. 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 2-34). 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 2-35).

Relay

Power c n/o Power

RIGHT
in Return

Suppressor

Relay

ACCEPTABLE Power c n/o Power

not recommended in Return
Power
Return

Suppressor

Relay

Power c n/o Power

WRONG
in Return

Suppressor

Figure 2-34. Installing Suppressors Across an AC Load

Relay

+ DC IN – DC RETURN
C N/O

IN4001 or equivalent

Figure 2-35. Installing a Diode Across a DC Load

Installation 2-69
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Setting Up High-speed Version of SmartPAC 2 with WPC 2000

If you have a standard SmartPAC 2 and wish to change the system to a high-speed version
(1600 SPM maximum), you will need to order SmartPAC 2 firmware with the high-speed
option. Contact Wintriss Tech. Support for details. When you receive the new firmware,
perform the following steps:
1. Install SmartPAC 2 firmware with the high-speed option according to the instructions in
Appendix D.
2. Locate jumper J102 on the SmartPAC 2 board (see Figure 2-25, page 2-51), and move the
jumper from the pins at the LOW setting to the pins at the HIGH setting.
3. Locate jumpers J125 and J126 on the WPC 2000 Main Processor board (see Figure 2-14,
page 2-28), and move the jumpers from the pins at the LO setting to the pins at the HI
setting.

Wiring a Remote Reset Switch

NOTICE
Wintriss recommends that you wire the Remote Reset switch to SmartPAC 2 rather than to WPC
2000. A Reset switch wired to WPC 2000 can reset only WPC 2000 faults. The same switch wired
to SmartPAC 2 can reset faults for both controls.

If you would like to be able to reset the SmartPAC 2 and WPC 2000 from a location remote
from their enclosures, the SmartPAC 2 board provides a terminal (i.e., pin #249 on TB107)
for wiring a remote Reset switch.
Connect a wire from terminal #249 on TB107 on the SmartPAC 2 board to a normally open
switch (see Figure 2-25, page 2-51, Table 2-25, below, and Figure 1 at the end of the manual).
Connect another wire from the switch to terminal #250 on TB107. SmartPAC 2 and WPC
2000 are reset with a momentary connection to ground.

Table 2-25. Remote Reset Switch Wiring Connections

SmartPAC 2 Board, TB107
Pin # Signal
249 Remote Reset input
250 Ground

Wiring a Sensor-Disabled Output (Optional)

You can wire a Sensor-disabled Output such as a warning light to a customer-supplied solid-
state 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
Power) on TB553 on the DiProPAC board (see Figure 2-29, page 2-58 and Figure 9 at the
back of the manual). Connect the negative input wire from the relay to terminal #306
(Auxiliary 1) on TB553. You cannot use more than 8 mA for your relay.

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Setting Up SmartPAC 2 with WPC 2000

! DANGER
PREVENT INJURY DURING SETUP
• Keep all personnel away from the press during setup.
• Be sure there is no die or other tooling in the press during setup.
Failure to comply with these instructions will result in death or serious injury.

CAUTION
PREVENT DAMAGE TO PRESS AND/OR DIE
Ensure that no die is mounted in the press during setup procedures.
Failure to comply with these instructions could result in property damage.

Turning on Power to SmartPAC 2 and WPC 2000

NOTICE
For help in using the SmartPAC 2 keyboard and display, see Chapter 3.

To turn on power to SmartPAC 2 and WPC 2000, do the following:

1. Make sure there is no die in the press.

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.

2. Turn the Program/Run key switch to the PROG position.

3. Power up the SmartPAC 2 and WPC 2000.
The green Power light on the SmartPAC 2 front panel illuminates, and a red SmartPAC 2
screen (see Figure 2-36, page 2-72) appears for a few seconds.

Installation 2-71
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Figure 2-36. SmartPAC 2 Startup Screen

When the startup screen disappears, the Brake Warning light begins to flash at
approximately two-second intervals as SmartPAC 2 completes its startup routine. This
can take up to one minute. Eventually, the Main Program Menu appears (see
Figure 2-37).

Figure 2-37. SmartPAC 2 Main Program Menu

NOTICE
• If the Program/Run key switch is set to RUN when you power up, the message “PRESS
CONTROL IS IN LOCKOUT MODE” is displayed on the screen. To clear the message,
turn the Stroke Select key switch to OFF, then to one of the other operating modes.
• If another error message displays when SmartPAC 2 starts up, press RESET.
• If the error message continues to appear after you press RESET, find the message in
Chapter 7 and follow the instructions for correcting the problem. If you cannot find the
message or cannot fix the problem, contact Wintriss Tech. Support.

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4. Press the “1” and “CLEAR” keys simultaneously and hold them down for a few seconds
until the Main Initialization Menu (see Figure 2-38) appears.

Figure 2-38. Main Initialization Menu

5. Verify that the “PRESS CONTROL” item appears in the menu, indicating that SmartPAC
2 is communicating with WPC 2000.
• If “PRESS CONTROL” does not appear in the menu, go to Problems at Startup (next).
• If “PRESS CONTROL” appears in the menu and you have the DiProPAC and/or
ProCamPAC option(s), go to Verifying Installation of DiProPAC and ProCamPAC,
page 2-74. If you don’t have one of these options, go to Creating and Loading a Test
Tool, page 2-76.

Problems at Startup
If one of the following problems occurs at startup, perform the accompanying instructions to
solve it.

SmartPAC 2 Display Remains Off

• If the green Power LED on the SmartPAC 2 front panel does not illuminate:
Turn off power to SmartPAC 2 and WPC 2000, and recheck all power connections. Check
to make sure that the connectors at both ends of the cables between the SmartPAC 2 board
and the display are correctly seated. Power up SmartPAC 2 and WPC 2000 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 WPC 2000, and check to make sure that the connectors at
both ends of the cables between the SmartPAC 2 board and the display are correctly seated.
Power up SmartPAC 2 and WPC 2000 again. If the display remains off, contact Wintriss
Tech. Support.

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“PRESS CONTROL” Does Not Appear in SmartPAC 2 Initialization Menu

1. Leaving power on, open the door of the WPC 2000 enclosure, and check the state of the
LEDs on the Main Processor board.
• If any of the LEDs are illuminated, the WPC 2000 has power. Go to step 2.
• If none of the LEDs are illuminated, power down the SmartPAC 2 and WPC 2000, and
check the AC wiring to the WPC 2000 (see page 2-9).
If the AC wiring checks out, power up both units. If no LEDs are illuminated, contact
Wintriss Tech. Support. If any LEDs are illuminated, go to the SmartPAC 2 Main
Initialization Menu and check for the presence of the “PRESS CONTROL” item.
If “PRESS CONTROL” is displayed in the menu, go to the next applicable section to
continue setting up your system.
If “PRESS CONTROL” is not displayed, go to step 2.
2. Leaving power on, open the door of the SmartPAC 2 enclosure, and check the state of the
LEDs labelled “Tx6” and “Rx6” on the SmartPAC 2 board (see Figure 2-25, page 2-51).
These two LEDs are located just to the left of TB105 on the right side of the board.
• If both LEDs are blinking, SmartPAC 2 and WPC 2000 are communicating. Check the
Main Initialization Menu again for the presence of the “PRESS CONTROL” item.
If “PRESS CONTROL” is displayed in the menu, go to the next applicable section to
continue setting up your system.
If “PRESS CONTROL” is not displayed, contact Wintriss Tech. Support.
• If the green “Rx6” LED is not blinking, power down SmartPAC 2 and WPC 2000, and
check the communications wiring (see page 2-52). If communications wiring checks
out, power up both units, access the Main Initialization Menu, and check for the
presence of the “PRESS CONTROL” item.
If the “PRESS CONTROL” item is displayed, go to the next applicable section to
continue setting up your system.
If “PRESS CONTROL” is not displayed, contact Wintriss Tech. Support.

Verifying Installation of DiProPAC and ProCamPAC

If you installed DiProPAC and/or ProCamPAC as part of your SmartPAC 2 system (see
page 2-56), you need to verify that the installation was done correctly and that these options
are available. To do so, perform the following steps:
1. Access the Main Initialization Menu (see Figure 2-38, page 2-73).
2. Move the highlight bar to INSTALLED OPTIONS, and press ENTER. The Installed
Options screen displays (see Figure 2-39, page 2-75 for an example).

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F1
F2
F3
F4
F5
F6
F7
F8

Figure 2-39. Installed Options Screen

3. Verify that “DiProPAC” and/or “ProCamPAC” are displayed in the installed options list.
• If the correct option(s) is displayed, go to the next section.
• If the correct option(s) is not displayed, go to page 2-56 and verify that you performed
the DiProPAC and/or ProCamPAC installation properly. Verify that the DiProPAC and/
or ProCamPAC board(s) is plugged into the correct connector(s). If the installation
checks out and the correct option(s) does not display, contact Wintriss Tech. Support.

Initializing WPC 2000 Parameters

NOTICE
INITIALIZE WPC 2000 PARAMETERS BEFORE PROGRAMMING SMARTPAC 2/WPC 2000
When you set up a new SmartPAC 2 with WPC 2000, initialize the WPC 2000 press parameters
before you start programming your unit.

NOTICE
RECORD WPC 2000 SETTINGS BEFORE INITIALIZING PARAMETERS
Use the Press Parameters Setup Sheet at the end of the manual to record your WPC 2000
settings before installing new firmware or initializing parameters.

NOTICE
Initializing press parameters resets them to their default values. Initialize press parameters only
when you set up a new SmartPAC 2 with WPC 2000 or install new WPC 2000 firmware.

When you first set up your SmartPAC 2 with WPC 2000 or when you install new WPC 2000
firmware, initialize press parameters on the Press Control Parameter Menu (see page 4-34 for
instructions).

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NOTICE
To access the Press Control Parameter Menu:
1. Turn the Program/Run key on the SmartPAC 2 front panel to PROG.
2. Press the “1” and “CLEAR” keys simultaneously and hold down a few seconds until the Main
Initialization Menu displays.
3. Move the highlight bar to the PRESS PARAMETERS item, using the Up () or Down ()
cursor key, and press ENTER.

If you install new WPC 2000 firmware in an existing system, record the WPC 2000
parameters before you install the new firmware. Re-enter the parameters after you
re-initialize the WPC 2000. See Chapter 3 for help using the SmartPAC 2 keyboard and
displays.

Creating and Loading a Test Tool

In order to set the direction of rotation of the resolver, zero the resolver, set the Top-stop
angle, install the overrun magnet, and perform other procedures covered in the remainder of
this chapter, you must be able to run the press. In order to run the press, you must create and
load a “test” tool, as instructed in the following steps.

NOTICE
• If you turn the Program/Run key switch and nothing happens, press RESET repeatedly until the
screen changes color, indicating that the SmartPAC 2 has changed to the mode you selected.
• If the message “PRESS CONTROL IS IN LOCKOUT MODE” is displayed on the screen, turn
the Stroke Select key switch to OFF, then to one of the other operating modes to clear it.

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.
2. Load the tool number (see Loading a Tool, page 5-5), and enter Run mode (see Entering
and Exiting Run Mode, page 6-2).

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Checking and Setting the Direction of Resolver Rotation

! DANGER
PREVENT INJURY DURING SETUP
• Keep all personnel away from the press during setup.
• Be sure there is no die or other tooling in the press during setup.
Failure to comply with these instructions will result in death or serious injury.

NOTICE
• If you turn the Program/Run key switch and nothing happens, press RESET repeatedly until the
screen changes color, indicating that the SmartPAC 2 has changed to the mode you selected.
• If the message “PRESS CONTROL IS IN LOCKOUT MODE” is displayed on the screen, turn
the Stroke Select key switch to OFF, then to one of the other operating modes to clear it.

To verify that the resolver rotates in the right direction, perform the following steps:
1. With a “test” tool loaded (see previous section), turn the Program/Run key switch to RUN.
2. Turn the Stroke Select key switch to INCH.
3. Inch the press by holding down, then releasing the Run/Inch palm switches on the
Operator Station. Observe the crankshaft angle displayed on the SmartPAC 2 screen.
• If the crankshaft angle increases as you inch the press (i.e., moves from 0° toward 359°),
the resolver is rotating in the right direction and wiring is correct. Go to the next
section.
• If the crankshaft angle decreases as you inch the press (i.e., moves from 359° toward
0°), the resolver is rotating in the wrong direction and wiring is incorrect.
Correct resolver wiring by swapping the black and yellow wires at both the WPC 2000
resolver connector, TB106, and the SmartPAC 2 resolver connector, TB101, referring to
Wiring the Resolver, page 2-25.
4. Inch the press again, and observe the crankshaft angle display.
• If the crankshaft angle increases, go to the next section.
• If the crankshaft angle decreases, contact Wintriss Tech. Support.

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Zeroing the Resolver

! DANGER
PREVENT INJURY DURING SETUP
• Keep all personnel away from the press during setup.
• Be sure there is no die or other tooling in the press during setup.
Failure to comply with these instructions will result in death or serious injury.

NOTICE
PRESS MUST BE AT TDC WHEN ZEROING RESOLVER
Verify that the press is at top dead center (i.e., 0° ± 2°) before you zero the resolver. If the press is
not at TDC, your timing settings may be wrong.

You must perform this procedure the first time you power up SmartPAC 2 and whenever you
install a new resolver. Zeroing the resolver ensures that SmartPAC 2 maintains an accurate
“zero” resolver position (i.e., as close to TDC as possible) by which it can time all its
operations. To zero the resolver, access the SmartPAC 2 Main Initialization Menu (see
Figure 2-37, page 2-72) and follow the instructions in the RESOLVER ZERO section,
page 4-3.

Setting the Top-stop “On” Angle and Installing the Overrun Magnet

! DANGER
PREVENT INJURY DURING SETUP
• Keep all personnel away from the press during setup.
• Be sure there is no die or other tooling in the press during setup.
Failure to comply with these instructions will result in death or serious injury.

! WARNING
INCORRECT INSTALLATION OF OVERRUN LIMIT SWITCH
Ensure that the overrun sensor magnet is installed at a proper location if you have Two-hand
Control without light curtains, or light curtains with muting. Proper installation of the magnet
ensures that if the Top-stop output relay fails, a hazardous situation will not occur on the
downstroke. The magnet must be mounted as close as possible to the Top-stop “On” Angle (see
page 2-82).
Failure to comply with these instructions could result in death or serious injury.

This section shows you how to install the magnet that, with the overrun sensor, makes up the
overrun limit switch. You should already have installed the overrun sensor (see page 2-29).
The overrun limit switch enables WPC 2000 to monitor operation of the resolver and to stop
the press whenever the resolver fails to work properly.

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The press cannot be run in Continuous or Single-stroke unless the overrun sensor and magnet
are installed and working correctly. Without the overrun limit switch, you can only operate
the press in Inch.
The angle at which you mount the magnet depends on the Top-stop “On” Angle, the angle at
which the Top-stop cam turns on, initiating a Top-stop. You must first determine and set the
Top-stop “On” Angle before installing the magnet.

Setting the Top-stop “On” Angle

In the following procedure, you

• Set the Top-stop “On” Angle to 270°
• Top-stop the press three times to determine an average angle at which the press stops
• Use the average angle value to calculate the actual Top-stop “On” angle
• Set the calculated Top-stop “On” Angle
To calculate and set the Top-stop “On” Angle, perform the following steps:

NOTICE
For a variable-speed press, you need to determine the latest Top-stop “On” Angle, which is the
angle at which the press top-stops at its slowest speed and with the shortest stopping angle/time.

NOTICE
BEFORE YOU SET THE TOP-STOP ANGLE, MAKE SURE THAT
• The press ram has been mechanically set to top dead center (TDC) (see NOTICE on page 2-3)
• The resolver has been aligned as close as possible to TDC (i.e., 0° ±2°) (see Mounting the
Resolver, page 2-25)
• The resolver has been zeroed (see page 2-78)

1. Make sure the following WPC 2000 features are set correctly:
• Option switches 1, 2, and 4 on switch block S101 on the WPC 2000 Main Processor
board should be set to OPEN (see page 4-35 for instructions).
When switches 1 and 2 are “open,” you can set any Top-stop Angle between 211° and
355°.
When switch 4 is “open,” the Auto Compensated Top Stop (ACTS) feature is disabled.
ACTS compensates for increases in press speed by adjusting the Top-stop Angle
backward (i.e., decreasing the angle).
• Pin #13 on the WPC 2000 Main Processor board should not be connected. When pin
#13 is unwired, Top-stop in Inch is enabled (see page 6-41).
• Micro-inch should be disabled (see page 4-29 for instructions).
2. Power down, then power up the SmartPAC 2 to enable the new settings.

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3. Clear the “PRESS CONTROL IS IN LOCKOUT MODE” message on the SmartPAC 2

display by turning the Stroke Select switch to OFF, then to INCH.
4. If you have a variable-speed press, set the press to the slowest production speed, but not
slower than 6 SPM.
5. Turn the Stroke Select key switch to RUN.
6. On the Main Run Menu, move the highlight bar to PRESS CONTROL, using the Up or
Down cursor key, and press ENTER. The Press Control Parameters screen displays (see
Figure 6-24, page 6-30) with the highlight bar resting on the TOP STOP ANGLE value.
7. Press ENTER to select the current Top-stop Angle setting, and when the Numeric Entry
window displays (see Figure 3-6, page 3-4), key in a value of 270°, or use the Up or Down
cursor key to adjust the current value to 270°, and press ENTER.
8. Press RESET to return to the Main Run Menu.
9. Press and hold the Run/Inch palm switches on the Operator Station so the press makes a
complete stroke and top-stops.
10. Observe the value displayed in the Crank Angle/SPM readout. The is the angle at which
the press top-stopped. Record this angle in the “Trial 1” box under step 1 in the Overrun
Sensor Magnet Installation Worksheet (see Figure 2-40, page 2-81).
11. Repeat step 9 at least two more times, and record the angle at which the press top-stops in
the “Trial 2” and “Trial 3” boxes in the Overrun Sensor Magnet Installation Worksheet.
12. Calculate the average angle at which the press top-stops from the three trials, and record
this value in the box in step 2 in the Overrun Sensor Magnet Installation Worksheet.
13. If the average angle reading is between 358° and 2°, the Top-stop “On” Angle is correct
and does not need to be adjusted. Go to Installing the Overrun Sensor Magnet, page 2-82.
If the average angle reading is greater than 180° but less than 358°, go to step 14.
If the average angle reading is greater than 2° but less than or equal to 180°, go to step 15.
If the some of the angle readings in steps 9 through 11 fall between 181° and 357° and
others between 3° and 180°, contact Wintriss Tech. Support.
14. When the average angle at which the press top-stops falls between 181° and 357°, perform
the following calculations, using the boxes in step 3a in the Overrun Sensor Magnet
Installation Worksheet:
• Subtract the Top-stop Angle setting you made on the Press Control Parameters screen in
step 7 (i.e., 270°) from the average angle reading. The difference is the number of
degrees it took the press to stop, or the press’s stopping angle.
• Subtract the stopping angle from 360°. The difference is the angle at which the
Top-stop cam turned on, or the Top-stop “On” Angle. Go to step 16.

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Overrun Sensor Magnet Installation Worksheet

To determine your press’s Top-stop “On” Angle, overrun magnet installation angle,
and option switch 1 and 2 settings, do the following:
1. With the Top Stop Angle set to 270°, cycle the press three times in Inch mode.
Record the angle at which the press top-stops each time.

° ° °
Trial 1 Trial 2 Trial 3
2. Calculate the average of the three trials, and record.

° Avergage angle at which press top-stops

3. Does the average angle at which the press top-stops occur before or after TDC?
Calculate the Top-stop “On” Angle as follows (a or b):
a. Angle at which press top-stops occurs before TDC (181° through 357°)

° – 270 ° = °
Average angle Top-stop Angle Setting Stopping Angle

360 ° – ° = °
Stopping Angle Top-stop “On” Angle
b. Angle at which press top-stops occurs after TDC (3° through 180°)

° – ° = °
Top-stop Angle Setting Average angle Top-stop “On” Angle

4. Determine the angle at which to install the overrun magnet (refer to Table 2-27).

°
5. Determine option switch 1 and 2 settings (refer to Table 2-27).

Switch 1 setting Switch 2 setting

Figure 2-40. Overrun Sensor Magnet Installation Worksheet

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15. When the average angle at which the press top-stops falls between 3° and 180°, subtract
the average angle reading from 270°, the Top-stop Angle setting you made on the Press
Control Parameters screen in step 7. The difference is the angle at which the Top-stop
cam turned on, or the Top-stop “On” Angle. Use the boxes in step 3b in the Overrun
Sensor Magnet Installation Worksheet for this calculation.
16. Turn the Program/Run key switch to PROG, access the Main Initialization Menu (see
Figure 2-38, page 2-73) by pressing the 1 and CLEAR keys at the same time for a second
or two, and select PRESS CONTROL to display the WPC Initialization Menu.
17. Select PRESS PARAMETERS on the WPC Initialization Menu to display the Press
Control Parameter Menu.
18. Enter the Top-stop “On” Angle value you calculated in step 14 or 15 in the TOP STOP
DEFAULT field on the Press Control Parameter Menu (see page 4-27 for instructions).

Installing the Overrun Sensor Magnet

The following procedure shows you how to

• Determine the correct angle at which to mount the overrun magnet, based on your Top-stop
“On” Angle calculations in the previous section
• Determine the setting for option switches 1 and 2, based on your Top-stop “On” Angle
calculations
• Install the magnet
Since the Top-stop cam stays on for 20°, the magnet must be mounted at an angle at least 20°
greater than the Top-stop “On” Angle you calculated and set in the previous procedure,
allowing the Top-stop cam to turn off before the overrun limit sensor turns on. Otherwise, an
“80” series fault will display on the SmartPAC 2 LCD (see Top-stop and Overrun Setting
Faults, page 7-21.)
Perform the following steps:
1. Determine the angle at which to install the overrun sensor magnet by consulting
Table 2-26. The first row of the table, labelled “Top-stop “On” Angle,” shows Top-stop
“On” Angle ranges (i.e., less than 240°, 241° to 270°, etc.). The second row shows the
angle at which the overrun sensor magnet should be mounted for each range (i.e., at 270°
if the Top-stop “On” Angle is less than 240°, at 300° if the Top-stop “On” Angle is
between 241° and 270°, etc.).

Table 2-26. Overrun Sensor Magnet Mounting Angle and Option Switch Settings
Top-stop “On” Angle < 240° 241° to 270° 271° to 300° > 301°
Magnet Mounting Angle 270° 300° 330° 359°
Switch 1 Setting ON ON OFF OFF
Switch 2 Setting ON OFF ON OFF

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Record in the box in step 4 of the Overrun Sensor Magnet Installation Worksheet (see
Figure 2-40, page 2-81) the correct mounting angle for the range within which your
calculated Top-stop “On” Angle falls (see step 18 of the previous procedure).
Example
You calculated in step 18 that your Top-stop “On” Angle is 284°, which falls in the 271° to
300° column in Table 2-26. The correct mounting angle for the overrun sensor magnet
would be 330°.
2. Determine the option switch 1 and 2 settings required for your calculated Top-stop “On”
Angle, referring to Table 2-26. Row 3 of the table shows option switch 1 settings for each
Top-stop “On” Angle range; row 4 shows option switch 2 settings. WPC 2000 uses these
settings to determine the angle at which to begin the overrun sensor closure test, which is
used to make sure that the overrun limit switch closes at the same angle on every stroke.
Record in the box in step 5 of the Overrun Sensor Magnet Installation Worksheet the
option switch 1 and 2 settings for the range within which your calculated Top-stop “On”
Angle falls.
Example
You calculated in step 18 that your Top-stop “On” Angle is 284°, which falls in the 271° to
300° column in Table 2-26. The correct switch settings would be OPEN for switch 1 and
CLOSED for switch 2.
3. Set option switches 1 and 2 to the positions you determined in step 2, referring to
page 4-35 for instructions.
4. If you are using the Auto Compensated Top Stop feature, return option switch 4 to its
CLOSED setting to enable it (see step 1 of the Setting the Top-stop “On” Angle
procedure).
5. Power down, then power back up SmartPAC 2 to enable the new option switch settings.
6. With the press in Inch mode, press the Run/Inch palm buttons until you have inched the
press to the angle you determined in step 1 (i.e., 270°, 300°, 330°, or 359°).
7. Using double-sided foam tape or other means, temporarily install the magnet directly
beneath the overrun sensor, referring to Mounting the Overrun Sensor Switch, page 2-30.
8. Check to make sure that the “Overrun limit Switch” LED in LED Group 6 on the WPC
2000 Main Processor board is lit, referring to the LED map in Figure 2-41, page 2-89 for
location. This LED illuminates when the overrun magnetic switch senses the magnet.

NOTICE
Make sure that the overrun limit switch has enough dwell to provide an adequate signal at
high speeds. Optimally, the magnet should actuate the switch for 15° to 25°. The larger
the diameter of the shaft on which the magnet is mounted, the shorter the dwell (see
Figure 2-16, page 2-30. The ideal shaft diameter is 4-6 in.

9. Run the press in Inch mode for about 4 strokes, viewing the overrun sensor’s On/Off
angles on each stroke. To display On/Off angles, select PRESS CONTROL on the Main

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Run Menu, then press F3 (Show Overrun Angles) on the Press Control Parameters screen
(see Figure 6-24, page 6-30).
Example
If you mounted the magnet at an angle of 330°, the magnetic switch might come “on” at,
say, 321°, and go “off” at 337°.
10. Run the press in Inch, Single-stroke, and Continuous modes for about 4 strokes each.
If the press cycles in every mode without a fault, go to step 11.
If a fault occurs while you are cycling the press in one or more modes, do the following:
• If a fault occurs on the first stroke after you install the magnet, press RESET and
execute another stroke.
• If the fault code is between F80 and F89 (or H80 through H89), there a problem with the
overrun sensor. Re-check your installation of the magnetic switch (see page 2-29) and
the magnet (see step 7) and your settings for option switches 1 and 2 (see steps 2 and 3),
then press RESET and run the press again for a few strokes. If the press stops and the
same error code displays, call Wintriss Tech. Support.
• If another fault code displays, look up the fault in Chapter 7 and follow the suggested
remedy. After correcting the problem, press RESET and run the press again for a few
strokes, checking for faults. If you need assistance, contact Wintriss Tech. Support.

! WARNING
INJURY FROM MAGNETS THAT DETACH
Mount the magnet with the brass screws provided. Plastic screws or adhesive could fail,
causing the magnet to become a dangerous projectile, especially on high-speed presses.
Failure to comply with these instructions could result in death or serious injury.

NOTICE
Use a brass or other non-ferrous screw to mount the magnet. Steel or ferrous screws can
cause false signals.

11. Permanently install the magnet in the position in which you temporarily mounted it in step
7. Drill and tap a hole, using a No. 36 drill and 6-32 tap. Mount the magnet, plastic side
up, with the 6-32 brass screw provided.
12. Cycle the press a few times in Single-stroke and Continuous modes to make sure it
operates without error.

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Installing Revised Firmware in WPC 2000

! DANGER
MACHINE MALFUNCTION AFTER INSTALLING REVISED SOFTWARE
Perform the final checkout (see page 2-87) tests after performing the firmware installation.
Failure to comply with these instructions could result in death or serious injury.

! 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.

To install revised firmware in WPC 2000, follow these steps:

1. Record the following WPC 2000 settings, using the Press Parameters Setup Sheet at the
back of the manual:
• Stop-time Limit (see page 4-30)
• Auto Carry-up Angle (see page 4-28)
• Top-stop Angle (see page 4-28)
• Micro-inch Time (see page 4-29)
• Cam On/Off settings (see page 6-19)
• Counter Preset (page 6-8)
• Counter (if necessary–see page 6-8)
2. Turn off power to WPC 2000.

CAUTION
STATIC DISCHARGE DAMAGE TO CHIP
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 that you are grounded, open the WPC 2000 enclosure and locate firmware
chips A (labelled “U111”) and B (labelled “U134”) on the Main Processor board (see
Figure 2-14, page 2-28). Note that each chip has a white label and a semi-circular notch at
one end. The notch on the chip faces in the same direction as the notch on its socket.

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NOTICE
Each new WPC 2000 firmware chip must be installed with the notch facing in the same
direction as the chip it is replacing.

CAUTION
If you use a screwdriver, be careful not to insert the screwdriver under the socket or you
may damage the board.
Failure to comply with these instructions could result in property damage.

4. Use a chip puller to remove the old chips, or insert a small screwdriver between the
bottom of the chips and their sockets and carefully pry the chips from the board. Put the
chips aside.
5. Making sure you are grounded, open the package containing the new firmware chips, and,
one at a time, remove the chips from their holders.

CAUTION
CHIP INSTALLED INCORRECTLY
• Install each chip with the notch facing in the same direction as the notch on the old
firmware chip; otherwise, when you power up the control, the chips will be destroyed.
• Align pins correctly with the socket before plugging chips in.
Failure to comply with these instructions could result in property damage.

6. Plug each chip into its socket, inserting the left row of pins first, then aligning the right
row of pins over the socket and pushing them in. Make sure that the notch in the chip
faces in the same direction as the notch in the old chip and that all of the pins are in the
socket.

NOTICE
If the two rows of pins are spread too far apart to plug easily into the socket, hold the chip
on its side on a flat surface with the pins pointing toward you. Being careful not to
overbend the pins, gently draw the top of the chip toward you until the pins bend a little.
Turn the chip over so that the other row of pins is now flat and pointing toward you. Draw
the top of the chip toward you again until the pins bend. When the rows of pins look
parallel, plug the chip into its socket again. If the chip still doesn't fit, repeat this procedure.

7. To verify that both chips are installed correctly, power up the WPC 2000 and SmartPAC 2.
• If the units power up normally, go to step 8.
• If the SmartPAC 2 LCD displays the message “A WPC 2000 WAS INSTALLED THE
LAST TIME THE UNIT WAS POWERED UP AND WAS NOT SEEN THIS TIME,”
one or more pins may be bent or not plugged in properly. Turn power off, and repeat the
procedure in the Notice for step 6 for each chip. Power the units up again. If WPC
2000 continues to malfunction, call Wintriss Tech. Support.

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8. Re-initialize the system, following the instructions starting on page page 4-34.

! DANGER
MAKE SURE THAT STOP-TIME LIMIT IS CORRECT AFTER INITIALIZATION
Whenever you initialize WPC 2000, the Stop-time Limit is reset to its factory value of 500
mS. Make sure to set the Stop-time Limit to a value based on the actual stopping time of
your press. Use the stopping time measured in the 90º stop-time test to calculate the
safety distance.
Failure to comply with these instructions will result in death or serious injury.

9. Re-program the settings you recorded in step 1.

Perform final checkout tests (next section).

Performing Checkout Tests

! DANGER
PREVENT INJURY DURING TESTING
• Keep all personnel away from the press during testing.
• Be sure there is no die or other tooling in the press during testing.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
INCORRECT INSTALLATION
• Perform the necessary checkout procedures according to the instructions in this manual.
• Correct any malfunctions before running the press.
• Ensure that all procedures are performed by qualified personnel.
Failure to comply with these instructions will result in death or serious injury.

! WARNING
ELECTRIC SHOCK HAZARD WHEN WORKING INSIDE ENCLOSURE WITH POWER ON
• DO NOT touch electrical connections or circuit boards.
• Use test equipment only on the terminals specified in the instructions.
• Ensure that the tests are performed by qualified personnel.
Failure to comply with these instructions could result in death or serious injury.

! WARNING
TOOLS OR OTHER MATERIAL IN THE DIE
Ensure that there are no tools or other material in or near the die before running the press.
Failure to comply with these instructions could result in death or serious injury.

Installation 2-87
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

NOTICE
PRESS MUST BE IN “TOP-STOP IN INCH” MODE WHEN PERFORMING CHECKOUT TESTS
Make sure that there is no connection to pin #13 on the WPC 2000 Main Processor board before
running checkout tests. Top-stop in Inch must be enabled when performing these tests. See
page 6-41 for further details.

This section provides the tests you need to perform to verify that your WPC 2000 is installed
and set up correctly. These tests must be performed before you proceed to Chapter 4.
Perform the tests in order, skipping tests for optional components that do not apply to your
WPC 2000 setup. Use the “test” tool you created for setup procedures (see page 2-76).
If your WPC 2000 fails a test, you will be directed to follow step-by-step procedures to isolate
and correct the problem. If you are unable to correct a problem, contact Wintriss Tech.
Support for assistance.
Do not run the press until the problem has been corrected. Do not attempt to replace any
components in your new WPC 2000 unless instructed to by Wintriss Tech. Support.
In order to run the tests, you need to know how to operate the press in Inch, Single-stroke, and
Continuous modes using Two-hand, One-hand, or Foot control. Refer to the instructions
starting on page 6-38 if you need help running the press using these settings.
Many of the tests ask you to check the state of LEDs on the WPC 2000 Main Processor board
and status indicators on the screens available from the Display WPC Input Status screen (see
Input Status, page 4-44). An LED map of the Main Processor board, showing the locations of
all LEDs, is provided in Figure 2-41, page 2-89. You access the Display WPC Input Status
screen by selecting PRESS CONTROL on the SmartPAC 2 Main Initialization Menu (see
Figure 2-38, page 2-73), then INPUT STATUS on the WPC Initialization Menu (see
Figure 4-18, page 4-23).

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+ 5 Logic B 86 - User input 10

G 85 - User input 8
R 84 - User input 6
O 83 - User input 4
+ 24 VDC U
P 82 - User input 2
All LEDs are red except ones that are
shaded, which are green. Pin numbers 87 - Light curtain A 2 input
associated with LEDs are shown in 7 77 - Light curtain A 1 input
bold. LEDs without pin numbers are
for internal connections. LED positions 76 - Mute lamp 2 output
on board are represented schematically.

66 - Mute lamp 1 output 75 - Unused input

G DSV B contact check G 74 - User input 9
R 88 - Light curtain B 2 input R 73 - User input 7
O DSV A contact check
O 72 - User input 5
U U
P DSV B drive check P 71 - User input 3
Lockout drive check 70 - Remote reset
5 Lockout contact check 6 26 - Unused input
DSV A drive check 24 - Overrun limit switch

22 - Top stop limit switch

21 - User input 1 20 - DSV monitor input
Aux B drive check 63 - Prior act B input
G G
R Aux A drive check R 19 - Unused input
O Aux A contact check O 18 - User input 11
U Aux B contact check
U 17 - Motor reverse input
P P
15 - Automatic actuator N/C 16 - Bar actuator input
3 14 - Foot switch N/O 4 60 - Top stop B2 input
12 - Palm switch B N/O 57 - E-stop B2 input
11 - Palm switch A N/O 13 - Top stop inch disable

52 - Top stop B1 input

G G
8 - Clutch air pressure sw. 6 - Bar selector switch
R R
O 78 - Light curtain B 1 input O 5 - Automatic actuator N/O
U 7 - Motor forward U 48 - E-stop B1 input
P P
Serial port Display bus 4 - Foot switch N/C 3 - One hand A

Transmit Receive 1 1 - Palm switch A N/C 2 2 - Palm switch B N/C

Receive Transmit + 5 Logic A

Figure 2-41. WPC 2000 LED Indicator Map (Center- or Right-mounted Board)

Installation 2-89
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

WPC 2000 Power Supply Test

! WARNING
ELECTRIC SHOCK HAZARD WHEN WORKING INSIDE ENCLOSURE WITH POWER ON
• DO NOT touch electrical connections or circuit boards.
• Use test equipment only on the terminals specified in the instructions.
• Ensure that this test is performed by qualified personnel.
Failure to comply with these instructions could result in death or serious injury.

To run the WPC 2000 power supply test, do the following, referring to Figure 2-41 for LED
locations on the WPC 2000 Main Processor board:
1. Set the Stroke Select key switch to OFF.
2. Open the front cover of the control enclosure or the door of your console.
3. Turn on power to WPC 2000.
4. On the WPC 2000 Main Processor board, check to see whether the +24 VDC, +5 Logic A,
and +5 Logic B LED indicators are illuminated.
• If all three LEDs are lit, go to the next applicable test.
• If all three LEDs are unlit, check to make sure that line voltage is being applied to the
system (see step 3), and correct any problems. If the LEDs are still unlit, call Wintriss
Tech. Support.
• If one or both of the +5 Logic LEDs are unlit, call Wintriss Tech. Support.

Checking Safeguarding Devices

! DANGER
DO NOT USE NON-SAFETY INTERLOCK SWITCHES IN SAFETY APPLICATIONS
• Ensure that all interlock switches used on safeguards are designed and rated for safety
applications. Check with the manufacturer to verify the rating of each interlock switch.
• Ensure that safety interlock switches are connected to control-reliable inputs if they are used for
safeguarding applications.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
PREVENT INJURY DURING TESTING
• Keep all personnel away from the press during testing.
• Be sure there is no die or other tooling in the press during testing.
• Use extreme caution when testing moveable guards. Keep hands and other body parts outside
the guarded area.
Failure to comply with these instructions will result in death or serious injury.

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Before turning on the press, check to verify the following conditions:

• All fixed safeguards prevent entry of a hand or other body part into the hazardous area.
• All moveable safeguards are correctly installed and wired to prevent operation of the press
when they are open and prevent entry of a hand or other body part into the hazardous area.
• All interlock switches used with safeguards are designed and rated for use in safety
applications. Check with the switch manufacturer to confirm their suitability for safety use.
• Interlock switches used for safeguarding are connected to control-reliable inputs.
• Any light curtains are installed at least the safety distance from the hazardous area and are
working properly.
• Any Two-hand controls used as safeguarding devices are mounted at least the safety
distance from the hazardous area.
• Safeguards are in place to prevent entry to the hazardous area under, over or around light
curtains or other safeguarding devices.
Test safeguarding devices as follows:
1. Run the press in Inch mode. Have someone else block the light curtain, if one is installed,
with an opaque object. The press should stop immediately.
• If the press stops, go to the next step.
• If the press does not stop, check the wiring of the light curtain and correct any problems.
Repeat the test. If the press still doesn’t stop, call Wintriss Tech. Support.
2. Run the press in Inch mode. Keeping hands outside the guarded area, have someone else
open one of the moveable guards just enough to open the interlock switch. The press
should stop immediately.
• If the press stops immediately when you open the guard, go to the next step.
• If the press does not stop, check the wiring of the moveable guard and correct any
problems. Repeat the test. If the press still doesn’t stop, call Wintriss Tech. Support.
3. Close the guard you just tested, reset the press control, and repeat step 2 for each
moveable guard. When you have tested all moveable guards, go to the next section.

Checking Dual Safety Valve (DSV) Wiring

! WARNING
PREVENT ELECTRIC SHOCK WHEN WORKING INSIDE THE ENCLOSURE
Turn off and disconnect power from the WPC 2000, the press and any other machinery it is
connected to before working inside the enclosure. This includes power to the press motor.
Failure to comply with these instructions could result in death or serious injury.

Follow the checkout procedure below to ensure that the dual safety valve is wired correctly.
Proper installation and operation of the DSV is crucial to personnel safety.
1. Power down the press and press control.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

2. On the DSV/Lockout Relay board (see Figure 2-14, page 2-28 for location), remove fuse
F302 or F303. F302 and F303 are the DSV fuses.
3. Power up the press and SmartPAC 2 with WPC 2000, select INCH with the Stroke Select
switch, and push both Run/Inch buttons. Observe what happens.
• If the ram does not move and the SmartPAC 2 display shows F79 or one of the DSV
faults (see page 7-19), the DSV is operating properly. Go to the next step.
• If the ram moves and/or the SmartPAC 2 display shows a fault other than F79 or one of
the DSV faults, check the wiring of the DSV and correct any problems, then repeat step
3. If the ram still moves and/or the display still shows a fault other than F79 or one of
the DSV faults, power down the press immediately, and call Wintriss Tech. Support.
4. Power down the press and SmartPAC 2 with WPC 2000.
5. On the DSV/Lockout Relay board, replace the DSV fuse (i.e., F302 or F303) you removed
in step 2, and remove the other DSV fuse.
6. Power up the press and SmartPAC 2 with WPC 2000, make sure the press is in Inch mode,
and push both Run/Inch buttons. Observe what happens.
• If the ram does not move and the SmartPAC 2 display shows F79 or one of the DSV
faults, the DSV is operating properly. Go to the next step.
• If the ram moves and/or the SmartPAC 2 display shows a fault other than F79 or one of
the DSV faults, check the wiring of the DSV and correct any problems, then repeat step
6. If the ram still moves and/or the display still shows a fault other than F79 or one of
the DSV faults, power down the press immediately and call Wintriss Tech. Support.
7. Power down the press and SmartPAC 2 with WPC 2000, and replace the fuse you
removed in step 5.
8. Power up the press and SmartPAC 2 with WPC 2000, make sure the press is still in Inch
mode, and push both Run/Inch buttons briefly. The ram should move.
• If the ram moves, go to the next section.
• If the ram does not move, check the wiring of the DSV and correct any problems.
Power up the press and SmartPAC 2 with WPC 2000. Push the Run/Inch buttons again.
If the ram still does not move, call Wintriss Tech. Support.

Checking the Emergency-stop Circuit

NOTICE
CHECKING THE EMERGENCY-STOP CIRCUIT IN SINGLE STROKE MODE
If your press does not run in Continuous mode, run this test while the press is making a stroke in
Single-stroke mode.

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To check the Emergency-stop circuit, do the following:

1. Run the press in Continuous mode, and press the Emergency Stop button on the Operator
Station. The press should Emergency-stop immediately.
• If the press Emergency-stops, repeat this test for every Emergency Stop button on the
press. If the press Emergency-stops every time, go to the next applicable test.
• If the press does not Emergency-stop, check the wiring of your E-stop circuit, correcting
any problems, and run the test again. If the press still does not Emergency-stop, call
Wintriss Tech. Support. Do not continue with this checkout procedure until the press
E-stops correctly.

NOTICE
RESET EMERGENCY-STOP BUTTON AFTER USE
The Emergency-stop button is not spring-loaded. You must pull it up to its original position to reset
the Emergency-stop (F13) fault.

Checking the Top-stop Circuit

NOTICE
CHECKING THE TOP-STOP CIRCUIT IN SINGLE-STROKE MODE
If your press does not run in Continuous mode, run this test while holding down the Run/Inch palm
buttons in Single-stroke mode.

To check the Top-stop circuit, do the following:

1. Run the press in Continuous mode, and press the Top Stop button on the Operator Station.
The press should stop at top dead center.
• If the press top-stops, repeat this test for every Top Stop button on the press. If the press
top-stops every time, go to the next applicable test.
• If the press does not top-stop, check the wiring of your Top-stop circuit, correcting any
problems, and run the test again. If the press still does not top-stop, call Wintriss Tech.
Support. Do not continue with this checkout procedure until the press top-stops
correctly.

System Static Test

! WARNING
ELECTRIC SHOCK HAZARD WHEN WORKING INSIDE ENCLOSURE WITH POWER ON
• DO NOT touch electrical connections or circuit boards.
• Use test equipment only on the terminals specified in the instructions.
• Ensure that this test is performed by qualified personnel.
Failure to comply with these instructions could result in death or serious injury.

Installation 2-93
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

To perform the system static test, do the following, referring to Figure 2-41 for LED locations
and Input Status, page 4-44 for instructions in how to access the Input Status screens:
1. Turn off the system air and bleed down the system air pressure to less than 35 PSI.
2. On the SmartPAC 2 front panel:
• Turn the Program/Run key switch to RUN.
• Turn the Stroke Select key switch of OFF.
• Select TWO HAND on the Mode Select Menu (see page 6-39)
• Turn the Stroke Select key switch to INCH.
3. Check to see whether the Interrupted Stroke message flashes on the SmartPAC 2 display.
• If the Interrupted Stroke message displays, go to the next step.
• If the Interrupted Stroke message does not display, check to see whether the “INCH
SEL” item on the WPC Buttons and Switches Input Status screen is ON (see
Figure 4-26, page 4-45). If “INCH SEL” shows an OFF status, check the wiring of the
Stroke Select switch and correct any problems. If “INCH SEL” is still OFF, call
Wintriss Tech. Support.
4. Press the Emergency Stop button on the Operator Station.
5. Check to see whether fault code F13 appears on the SmartPAC 2 display.
• If F13 displays, go to the next step.
• If F13 does not display, check to see whether the “E-stop A input” and “E-stop B input”
LEDs on the WPC 2000 Main Processor board turn off when the Emergency Stop
button is pressed. If the two LEDs do not turn off, check the wiring of the E-stop A and
E-stop B input connections, and correct any problems. If the two LEDs still do not turn
off, call Wintriss Tech. Support.

NOTICE
RESET EMERGENCY-STOP BUTTON AFTER USE
The Emergency-stop button is not spring-loaded. You must pull it up to its original position
to reset the Emergency-stop (F13) fault.

6. Turn on the press motor in forward rotation (if applicable).

7. Check to see whether the “Motor forward” LED on the WPC 2000 Main Processor board
is lit.
• If the “Motor forward” LED is lit, go to the next step.
• If the “Motor forward” LED is unlit, check the wiring of the Motor Forward input
connection, and correct any problems. If the LED is still unlit, call Wintriss Tech.
Support.
8. Press both Run/Inch palm buttons on the Operator Station at the same time.

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9. Check to see whether fault code F48 appears on the LED display.

NOTICE
If the E-stop and Top-stop circuits are not connected according to the wiring shown in
Figure 2 at the end of the manual, the fault code that displays may be different. Call
Wintriss Tech. Support for assistance.

• If F48 displays, go to the next step.

• If F48 does not display, check to see whether the “System air pressure” LED on the
WPC 2000 Main Processor board is unlit. If the LED is unlit, check the wiring of the
system air pressure switch input and correct any problems. Press both Run/Inch palm
buttons again. If F48 still does not display, call Wintriss Tech. Support.
10. Apply system air pressure to the press.
11. Check to see whether the “System air pressure” LED on the WPC 2000 Main Processor
board is lit. Clear the error code on the display by pressing RESET.
12. Turn off the counterbalance air and bleed down the counterbalance air pressure.
13. Press both Run/Inch palm buttons on the Operator Station at the same time. The ram
should not move, and the fault code associated with the input the counterbalance pressure
switch is connected to (normally, F54 for User 4 Input) should display.
• If the ram does not move and the appropriate fault code appears, restore the
counterbalance air, press RESET, and go to the next step.
• If the ram moves and/or the appropriate fault code does not display, check the wiring of
the counterbalance air pressure switch input, and correct any problems. Push both Run/
Inch palm buttons again. If the ram still moves and/or the appropriate fault code still
does not display, call Wintriss Tech. Support.

NOTICE
If the E-stop and Top-stop circuits are not connected according to the wiring shown in
Figure 2 at the end of the manual, the fault code that displays may be different. Call
Wintriss Tech. Support for assistance.

14. Press the Emergency Stop button on the Operator Station.

• If fault code F13 displays, go to the next applicable test.
• If F13 does not display, contact Wintriss Tech. Support.

Installation 2-95
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Anti-tiedown Test

! DANGER
INJURY DURING TESTING
• Keep all personnel away from the press during testing.
• Be sure there is no die or other tooling in the press during testing.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
OPERATOR STATION MAY NOT MEET SAFETY REQUIREMENTS
• Ensure that the Operator Station is wired correctly.
• Ensure that on any non-Wintriss Operator Station the Run buttons are placed so that two hands
are required to push both buttons at the same time and no one can press both buttons with one
hand or with one hand and one elbow.
• Ensure that on any non-Wintriss Operator Station the Run buttons have ring guards or other
means in place to prevent unintentional operation.
Failure to comply with these instructions will result in death or serious injury.

The anti-tiedown test verifies that the Operator Station is installed correctly and is wired so
that both hands are needed to press the Run/Inch buttons simultaneously. To perform the test,
do the following:
1. On the SmartPAC 2 front panel:
• Turn the Program/Run key switch to RUN.
• Turn the Stroke Select key switch of OFF.
• Select TWO HAND on the Mode Select Menu (see page 6-39)
• Turn the Stroke Select key switch to SINGLE STROKE.
2. Press and hold down both Run/Inch palm buttons to cycle the press through one stroke.
When the press top-stops, continue to hold down the left button, and remove your hand
from the right button; then, after a moment, replace your hand on the right button and
continue to hold down both buttons.
• If the press does not initiate the stroke, go to the next step.
• If the press does initiate the stroke, check the wiring of the palm buttons. When the
problem has been corrected, repeat step 2. If the press still initiates the stroke, call
Wintriss Tech. Support.
3. Remove both hands from the Run/Inch buttons.
4. Press and hold down both Run/Inch buttons to cycle the press through one stroke. When
the press top-stops, continue to hold down the right button, and remove your hand from
the left button; then, after a moment, replace your hand on the left button and continue to
hold down both buttons.
• If the press does not initiate the stroke, the test has been completed successfully. Go to
the next applicable test.

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• If the press does initiate the stroke, check the wiring of the palm buttons, correcting any
problems, then repeat step 4. If the press still initiates the stroke, call Wintriss Tech.
Support.

Anti-repeat Test

! DANGER
INJURY DURING TESTING
• Keep all personnel away from the press during testing.
• Be sure there is no die or other tooling in the press during testing.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
OPERATOR STATION MAY NOT MEET SAFETY REQUIREMENTS
• Ensure that the Operator Station is wired correctly.
• Ensure that on any non-Wintriss Operator Station the Run buttons are placed so that two hands
are required to push both buttons at the same time and no one can press both buttons with one
hand or with one hand and one elbow.
• Ensure that on any non-Wintriss Operator Station the Run buttons have ring guards or other
means in place to prevent unintentional operation.
Failure to comply with these instructions will result in death or serious injury.

The anti-repeat test verifies that the press cycles only once when WPC 2000 is in
Single-stroke mode and both Run/Inch buttons are pressed simultaneously. To perform the
test, do the following:
1. On the SmartPAC 2 front panel:
• Turn the Program/Run key switch to RUN.
• Turn the Stroke Select key switch of OFF.
• Select TWO HAND on the Mode Select Menu (see page 6-39)
• Turn the Stroke Select key switch to SINGLE STROKE.
2. Press and hold down both Run/Inch palm buttons until the press completes a stroke and
for ten seconds after the press stops.
• If the press makes one stroke and then top-stops, WPC 2000 is operating correctly. Go
to the next applicable test.
• If the press cycles again after making one stroke, check the wiring of the Operator
Station and correct any problems; then, repeat the test. If the press still cycles after it
makes one stroke, call Wintriss Tech. Support.

Installation 2-97
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Shadow Light Curtain Test

! WARNING
ELECTRIC SHOCK HAZARD WHEN WORKING INSIDE ENCLOSURE WITH POWER ON
• DO NOT touch electrical connections or circuit boards.
• Use test equipment only on the terminals specified in the instructions.
• Ensure that this test is performed by qualified personnel.
Failure to comply with these instructions could result in death or serious injury.

WPC 2000 tests whether its light curtain inputs are working properly whenever the press is
started and stopped.
Perform the following test to verify that your Shadow light curtain is installed and wired
correctly and operating properly, referring also to the troubleshooting information in your
light curtain user manual if necessary. If you have more than one light curtain on your press,
perform this test on each light curtain.
1. Power up the light curtain.
2. Check to see whether there is power to the Shadow. On Shadow V and Shadow VI units,
the amber (Power On) LED on the transmitter indicates that the light curtain has power.
On Shadow VII units, the presence of power is indicated by an illuminated diagnostic
code LED display. The green Power LED on the optional Shadow 8 control or the LEDs
on Shadow 8 Main Receiver and Transmitter indicate the presence of power.
• If the Shadow has power, go to the next step.
• If the Shadow does not have power, turn off the light curtain, and check the input power
wiring and the power fuse. (The fuse is located in the Shadow V receiver or in the
Shadow VI, Shadow VII, or Shadow 8 (optional) control box. The Shadow VII DIN
controller has no fuse.) Rewire power connections and/or replace the fuse if necessary.
Power up again. (On Shadow V and Shadow VI units, if there is still no power, turn off
the transmitter and try replacing the amber indicator. Power up again.) If there is still
no power to the unit, call Wintriss Tech. Support.
3. At the Shadow receiver, check to see whether the green (Curtain Unobstructed) indicator
is lit.
• If the green indicator is lit, go to the next step.
• If the receiver’s red (Curtain Obstructed) indicator is lit, realign the light curtain heads.
If the red indicator is still lit, check the interrupt circuit (Shadow V and Shadow VI) or
the Light Curtain Test mode jumper (Shadow VII and Shadow 8). To check the
interrupt circuit, make sure that the following terminal reads 0 V relative to ground:
Shadow V: INT terminal in the transmitter (see Figure 4 at end of manual)
Shadow VI: pin #19 on auxiliary TB4 in the control (see Figure 14 at end of manual)
Shadow VI/WPC Interface Board: pin #5 on TB4 (see Figure 15 at end of manual)

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If the applicable terminal does not read 0 V relative to ground, check and correct the
ground wiring for the unit.
The Light Curtain Test Mode jumper (JP124 for Light Curtain 1, JP122 for Light
Curtain 2–see Figure 2-14, page 2-28 for location on the WPC 2000 Main Processor
board), should be positioned at the “INT” setting when Shadow VII or Shadow 8 light
curtains are installed. Reposition the jumper to the correct setting if necessary. The
Light Curtain Output Type jumper (JP123 for Light Curtain 1, JP121 for Light Curtain
2) should be set to “PNP.”
If the red indicator is still illuminated, call Wintriss Tech. Support.
• If both the receiver’s green and red indicators are unlit, power down the unit and check
the wiring to the receiver. Also check the power fuse (located in the Shadow V receiver,
in the Shadow VI, Shadow VII, or Shadow 8 (optional) control box, not present in the
Shadow VII DIN control), and replace if necessary. Power up again. If the receiver’s
green and red indicators are still off, replace them. If none of these remedies corrects
the problem, call Wintriss Tech. Support.
4. Block the light curtain. On the receiver, the green indicator should turn off and the red
indicator should illuminate.
• If the receiver’s green indicator goes off and the red indicator comes on, go to the next
step.
• If the receiver’s green indicator stays on when the curtain is blocked, check receiver
wiring, and repeat step 4. If the green indicator is still lit, call Wintriss Tech. Support.
5. Remove the obstruction from the light curtain. At the receiver, verify that the red
indicator goes off and the green indicator comes on.
6. Go to the next applicable test.

Single-stroke Mode Test with Light Curtain(s)

! DANGER
INJURY DURING TESTING
• Keep all personnel away from the press during testing.
• Be sure there is no die or other tooling in the press during testing.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
CONTINUOUS MODE USED ON PRESS NOT GUARDED PROPERLY FOR CONTINUOUS
Disconnect the “Continuous” position on the Stroke Select switch to prevent your press from being
run in Continuous mode if it is not guarded correctly for use in Continuous mode. Also cover the
“CONT” label on your control’s Stroke Select switch.
Failure to comply with these instructions will result in death or serious injury.

Installation 2-99
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

! WARNING
ELECTRIC SHOCK HAZARD WHEN WORKING INSIDE ENCLOSURE WITH POWER ON
• DO NOT touch electrical connections or circuit boards.
• Ensure that this test is performed by qualified personnel.
Failure to comply with these instructions could result in death or serious injury.

To test Single-stroke mode when light curtains are installed, perform the following steps,
referring to Figure 2-41 for LED locations and Input Status, page 4-44 for instructions in how
to access the Input Status screens. To verify Single-stroke operation on a press without light
curtains, go to the next test (page 2-102).
1. On the SmartPAC 2 front panel:
• Turn the Program/Run key switch to RUN.
• Turn the Stroke Select key switch of OFF.
• Select TWO HAND on the Mode Select Menu (see page 6-39)
• Turn the Stroke Select key switch to SINGLE STROKE.
Verify that the “S.S. SEL” item on the WPC Buttons and Switches Input Status screen is
ON (see Figure 4-26, page 4-45).
2. Verify that the light curtain is unobstructed and that the “Light curtain A1 input” and
“Light curtain A2 input” LEDs on the WPC 2000 Main Processor board are lit. (If you are
testing a second pair of light curtains, verify that “Light curtain B1 input” and “Light
curtain B2 input” LEDs are lit.) These LEDs turn off when the light curtain is obstructed.
3. Press and hold both Run/Inch palm buttons on the Operator Station, observing the ram’s
motion.
• If the ram makes a complete stroke, stopping at top dead center, go to the next step.
• If the ram moves but does not make a complete stroke or does not stop at top dead
center and a fault code between F80 and F89 (or between H80 and H89) displays, there
is a problem with the overrun limit switch. Try the remedies suggested for overrun limit
switch faults, starting on page 7-21; then, inch the ram to the top of the stroke and repeat
this test. If the ram still does not make a complete stroke or does not stop at top dead
center, call Wintriss Tech. Support.
• If the ram moves but does not make a complete stroke or does not stop at top dead
center and an overrun limit switch fault does not display, check the wiring of the palm
buttons and light curtains, correcting any problems; then, inch the ram to the top of the
stroke, and repeat the test. If the ram still does not make a complete stroke or does not
stop at top dead center, call Wintriss Tech. Support.
• If the ram does not move at all, check to make sure that the correct version of WPC
2000 firmware is installed, and check the wiring of the palm buttons, correcting any
problems. Re-run the test, starting with step 1. If the ram still does not move when you
press the Run/Inch palm buttons, call Wintriss Tech. Support.

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4. Interrupt the light curtain by placing a piece of cardboard or other object between the light
curtain heads to block at least two inches of the light field. Leave the object in place while
you perform step 5.
5. Press and hold both Run/Inch palm buttons, observing the behavior of the ram.
• If the ram does not move and you have only one light curtain, go to the next step.
• If the ram does not move and you have two light curtains, repeat the test, starting with
step 4, removing the obstruction from the first light curtain and blocking the second
light curtain. Once the test on the second light curtain is successful, go to the next step.
• If the ram does move, check to make sure the correct version of WPC 2000 firmware is
installed, and check the wiring of the palm buttons and light curtains, correcting any
problems. Re-run the test, starting with step 4. If the ram still moves with the light
curtain blocked, call Wintriss Tech. Support.
6. Remove the object you used to interrupt the light curtain field in step 4. Prepare to insert
it into the field while the ram is on the downstroke. Be sure to keep hands and other
objects away from the press.
7. While one person presses and holds both Run/Inch palm buttons, have another person
move the cardboard or other object into the light field while the ram is on the downstroke.
Observe the action of the ram.
• If you are using one light curtain, and the ram stops immediately and the Interrupted
Stroke message flashes on the SmartPAC 2 display, go to the next step.
• If you are using two light curtains, and the ram stops immediately and the Interrupted
Stroke messages displays, inch the ram to the top of the stroke and repeat the test by
interrupting the second light curtain, starting with step 6. When you have successfully
completed the test with the second light curtain, go to the next step.
• If the ram does not stop immediately, check the wiring of the light curtains, correcting
any problems; then, inch the ram to the top of the stroke and re-run the test, starting with
step 6. If the ram again moves when the light curtain is interrupted, call Wintriss Tech.
Support.
8. Clear the Interrupted Stroke by holding the Run/Inch palm buttons until the ram stops at
top dead center.
9. Press and immediately release the Run/Inch palm buttons, observing the behavior of the
ram.
• If the ram moves when you press the Run/Inch palm buttons, then stops when you
release them, and the Interrupted Stroke message displays, go to the next step.
• If the ram does not move, or if it moves but does not stop immediately when you release
the Run/Inch palm buttons, or if the Interrupted Stroke message does not display, check
the wiring of the palm buttons and light curtains, correcting any problems, and run this
test again, repeating step 9. If the ram still does not move or moves but does not stop
immediately, or if the ram stops but the Interrupted Stroke message does not display,
call Wintriss Tech. Support.
10. Complete the stroke by pressing and holding the Run/Inch palm buttons.

Installation 2-101
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

11. Go to the next applicable test.

Single Stroke Mode Test without Light Curtain(s)

! DANGER
INJURY DURING TESTING
• Keep all personnel away from the press during testing.
• Be sure there is no die or other tooling in the press during testing.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
CONTINUOUS MODE USED ON PRESS NOT GUARDED PROPERLY FOR CONTINUOUS
Disconnect the “Continuous” position on the Stroke Select switch to prevent your press from being
run in Continuous mode if it is not guarded correctly for use in Continuous mode. Also cover the
“CONT” label on your control’s Stroke Select switch.
Failure to comply with these instructions will result in death or serious injury.

To test Single-stroke mode when light curtains are not installed, perform the following steps,
referring to Figure 2-41 for LED locations and Input Status, page 4-44 for instructions in how
to access the Input Status screens:
1. On the SmartPAC 2 front panel:
• Turn the Program/Run key switch to RUN.
• Turn the Stroke Select key switch of OFF.
• Select TWO HAND on the Mode Select Menu (see page 6-39)
• Turn the Stroke Select key switch to SINGLE STROKE.
Verify that the “S.S. SEL” item on the WPC Buttons and Switches Input Status screen is
ON (see Figure 4-26, page 4-45).
2. Press and hold both Run/Inch palm buttons, observing the motion of the ram.
• If the ram makes a complete stroke and stops at or near top dead center, go to step 6.
• If the ram does not make a full stroke or does not stop at top dead center, go to the next
step.
3. Check for fault codes on the SmartPAC 2 display.
• If a fault code between F80 and F89 (or between H80 and H89) displays, there is a
problem with the overrun limit switch. Try the remedies suggested for overrun limit
switch faults, starting on page 7-21; then, inch the ram to the top of the stroke and run
the test again, starting with step 2. If the ram still does not make a complete stroke or
does not stop at top dead center, call Wintriss Tech. Support.
• If the SmartPAC 2 display shows no error or an error other than an overrun limit switch
fault, check and correct the wiring of the palm buttons and light curtains, correcting any
problems; then, run the test again, starting with step 2. If the ram still does not complete
a stroke or stop at top dead center, call Wintriss Tech. Support.

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4. Turn the Stroke Select switch to INCH, and bring the ram to top dead center. Verify that
the “INCH SEL” item on the WPC Buttons and Switches Input Status screen is ON (see
Figure 4-26, page 4-45).
5. Press and then immediately release the Run/Inch palm buttons, observing the behavior of
the ram.
• If the ram moves when you press the Run/Inch buttons, then stops when you release
them, and the Interrupted Stroke message flashes on the SmartPAC 2 display, go to the
next step.
• If the ram does not move, or if it moves but does not stop immediately when you release
the Run/Inch buttons, or if the Interrupted Stroke message does not display, check the
wiring of the palm buttons and light curtains, correcting any problems, and run the test
again, repeating step 5. If the ram still does not move or moves but does not stop
immediately, or if the ram stops but the Interrupted Stroke message does not display,
call Wintriss Tech. Support.
6. Complete the stroke by pressing and holding the Run/Inch palm buttons.
7. Go to the next applicable test.

Continuous Mode Test with Light Curtain(s)

! DANGER
IMPROPER SAFEGUARDING
• Install safeguarding devices as needed to ensure operator safety. Follow the machine guarding
requirements of OSHA regulation 1910.217 and any other regulations and standards that apply.
• Ensure that guarding is properly installed to prevent access to the machine over, under or
around any guarding device.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
INJURY DURING TESTING
• Keep all personnel away from the press during testing.
• Be sure there is no die or other tooling in the press during testing.
Failure to comply with these instructions will result in death or serious injury.

! WARNING
ELECTRIC SHOCK HAZARD WHEN WORKING INSIDE ENCLOSURE WITH POWER ON
• DO NOT touch electrical connections or circuit boards.
• Ensure that this test is performed by qualified personnel.
Failure to comply with these instructions could result in death or serious injury.

Installation 2-103
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

This test verifies that your press and the light curtains connected to it operate correctly in
Continuous mode. To verify Continuous mode operation on a press without light curtains, go
to the next test (page 2-106). If your press does not run in Continuous mode, go to the next
applicable test. To run the Continuous mode test with light curtains, do the following,
referring to Figure 2-41 for LED locations and Input Status, page 4-44 for instructions in how
to access the Input Status screens:
1. On the SmartPAC 2 front panel:
• Turn the Program/Run key switch to RUN.
• Turn the Stroke Select key switch of OFF.
• Select TWO HAND on the Mode Select Menu (see page 6-39)
• Turn the Stroke Select key switch to CONT.
Verify that the “CONT SEL” item on the WPC Buttons and Switches Input Status screen
is ON (see Figure 4-26, page 4-45).
2. Verify that the light curtain is unobstructed and that the “Light curtain A1 input” and
“Light curtain A2 input” LEDs on the WPC 2000 Main Processor board are lit. (If you are
testing a second pair of light curtains, verify that “Light curtain B1 input” and “Light
curtain B2 input” LEDs are lit.) These LEDs turn off when the light curtain is obstructed.
3. Press the Prior Act button on the Operator Station. The Prior Act lamp should illuminate,
then turn off after eight seconds.
• If the Prior Act lamp turns off after eight seconds, go to step 4.
• If the Prior Act lamp does not turn off after eight seconds, stop! Do not go any further!
Call Wintriss Tech. Support.
4. Press the Prior Act button and, before the indicator lamp goes out, press both Run/Inch
palm buttons, releasing them after bottom dead center on the first stroke. The press should
continue running.
• If the press continues to run, go to the next step.
• If the press stops, check the wiring of the palm buttons, correct any problems, press and
hold both Run/Inch buttons to return the ram to top dead center, and run the test again.
If the press still stops, call Wintriss Tech. Support.
5. Press the Emergency Stop button on the Operator Station. The ram should stop
immediately, the F13 fault code should appear on the SmartPAC 2 LCD, and the
Interrupted Stroke message should display. If these conditions are not present, check the
wiring of the Operator Station, particularly the E-stop wiring, and correct any problems.
Rerun this test from step 4. If the conditions are still not present, call Wintriss Tech.
Support.

NOTICE
RESET EMERGENCY-STOP BUTTON AFTER USE
The Emergency-stop button is not spring-loaded. You must pull it up to its original position
to reset the Emergency-stop (F13) fault.

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NOTICE
When a stroke is interrupted, WPC 2000 automatically switches to Two-hand Maintained
Single-stroke mode for the remainder of the stroke.

6. Press and hold the Run/Inch palm buttons until the press returns to top dead center.
7. Press the Prior Act button and, before the indicator lamp goes out, press both Run/Inch
palm buttons, releasing them after bottom dead center on the first stroke. The press should
continue running.
8. Press the Top Stop button on the Operator Station. The ram should stop near top dead
center. If the ram does not stop at TDC, check the wiring of the Operator Station,
particularly the top-stop wiring, and correct any problems. Rerun this test from step 7. If
the ram still does not top-stop, call Wintriss Tech. Support.
9. Restart the press in Continuous mode.
10. Block the light curtain. The press should come to an immediate stop, and the Interrupted
Stroke message should display.
• If the press comes to an immediate stop and the Interrupted Stroke message displays, go
to the next step.
• If your WPC 2000 has the muting option, and the ram stops as soon as it reaches the
non-muted (i.e., downward) portion of the stroke, go to the next step.
• If your WPC 2000 has the muting option, and the ram does not stop in the non-muted
portion of the stroke, check the wiring of the light curtain, correcting any problems, and
run the test again, starting with step 9. If the ram still does not stop in the non-muted
part of the stroke, call Wintriss Tech. Support.
• If your WPC 2000 does not have the muting option and the press does not come to an
immediate stop when you interrupt the light curtain, check the wiring of the light
curtain, correcting any problems, and run the test again, starting with step 9. If the press
still does not stop immediately, call Wintriss Tech. Support.
11. Press and hold both Run/Inch palm buttons to return the ram to top dead center.
12. Go to the next applicable test.

Installation 2-105
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Continuous Mode Test without Light Curtain(s)

! DANGER
IMPROPER SAFEGUARDING
• Install safeguarding devices as needed to ensure operator safety. Follow the machine guarding
requirements of OSHA regulation 1910.217 and any other regulations and standards that apply.
• Ensure that guarding is properly installed to prevent access to the machine over, under or
around any guarding device.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
INJURY DURING TESTING
• Keep all personnel away from the press during testing.
• Be sure there is no die or other tooling in the press during testing.
Failure to comply with these instructions will result in death or serious injury.

This test verifies that your press operates correctly in Continuous mode. To verify
Continuous mode operation on a press with light curtains, return to the previous test (see
page 2-103). If your press does not run in Continuous mode, go to the next applicable test.
To run the Continuous mode test without light curtain, do the following, referring to
Figure 2-41 for LED locations and Input Status, page 4-44 for instructions in how to access
the Input Status screens:
1. On the SmartPAC 2 front panel:
• Make sure the Program/Run key switch is set to RUN.
• Turn the Stroke Select key switch of OFF.
• Select TWO HAND on the Mode Select Menu (see page 6-39)
• Turn the Stroke Select key switch to CONT.
Verify that the “CONT SEL” item on the WPC Buttons and Switches Input Status screen
is ON (see Figure 4-26, page 4-45).
2. Press the Prior Act button on the Operator Station. The Prior Act lamp should illuminate,
then turn off after eight seconds.
• If the Prior Act lamp turns off after eight seconds, go to the next step.
• If the Prior Act lamp does not turn off after eight seconds, stop! Do not go any further!
Call Wintriss Tech. Support.
3. Press the Prior Act button and, before the indicator lamp goes out, press both Run/Inch
palm buttons, releasing them after bottom dead center on the first stroke. The press should
continue running.
• If the press continues to run, go to the next step.
• If the press stops, check the wiring of the palm buttons, and correct any problems. Run
the test again. If the press still stops, call Wintriss Tech. Support.

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4. Press the Emergency Stop button on the Operator Station. The ram should stop
immediately, the F13 fault code should appear in the LED display, and the Interrupted
Stroke message should display. If these conditions are not present, check the wiring of the
Operator Station, particularly the E-stop wiring, and rerun this test from step 3. If the
conditions are still not present, call Wintriss Tech. Support.

NOTICE
RESET EMERGENCY-STOP BUTTON AFTER USE
The Emergency-stop button is not spring-loaded. You must pull it up to its original position
to reset the Emergency-stop (F13) fault.

NOTICE
When a stroke is interrupted, WPC 2000 automatically switches to Two-hand Maintained
Single-stroke mode for the remainder of the stroke.

5. Press and hold the Run/Inch palm buttons until the press returns to top dead center.
6. Press the Prior Act button and, before the indicator lamp goes out, press both Run/Inch
palm buttons, releasing them after bottom dead center on the first stroke. The press should
continue running.
7. Press the Top Stop button on the Operator Station. The ram should stop near top dead
center. If the ram does not stop at TDC, check the wiring of the Operator Station,
particularly the top-stop wiring, and correct any problems. Rerun this test from step 6. If
the ram still does not top-stop, call Wintriss Tech. Support.
8. If the die space is safeguarded with doors or gates with interlocking circuits, open a door/
gate and try starting the press. The press should not start and an F13 (see page 7-8), or
F17 or F18 (see page 7-9) error should display. Close the door/gate, reset the error, and
start the press. While the press is running, open the door/gate. The press should stop
immediately and display F13, F17, or F18. If the press does not stop, check the wiring of
the interlock switch and the switch itself for proper functioning.
9. Go to the next applicable test.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Foot Switch Test

! DANGER
INJURY DURING TESTING
• Keep all personnel away from the press during testing.
• Be sure there is no die or other tooling in the press during testing.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
MISSING SAFEGUARDS
Install a light curtain for use with the Foot Switch option. A light curtain is required for using the
Foot Switch.
Failure to comply with these instructions will result in death or serious injury.

This test, which should be run only if you have an optional Foot Switch, verifies that your
Foot Switch is operating properly. To perform the test, do the following, referring to
Figure 2-41 for LED locations and Input Status, page 4-44 for instructions in how to access
the Input Status screens:

NOTICE
These instructions refer to the Auto Carry-up Angle, which is factory set to one of the following
values:
• 170° if the press does not have a light curtain
• 149° if the press does have a light curtain
Refer to Setting the Auto Carry-up Angle, page 4-28 for information about the Auto Carry-up
feature.

1. On the SmartPAC 2 front panel:

• Make sure the Program/Run key switch is set to RUN.
• Turn the Stroke Select key switch of OFF.
• Select FOOT on the Mode Select Menu (see page 6-39)
• Turn the Stroke Select key switch to SINGLE STROKE.
Verify that the “S.S. SEL” and “FOOT N/C” items on the WPC Buttons and Switches
Input Status screen are ON (see Figure 4-26, page 4-45).
2. Make sure that option switch 3 on the WPC 2000 Main Processor board is set to OPEN, its
default setting (see Enabling Foot Control in a Foot Switch, page 4-37).
3. Power down, then power back up the WPC 2000, if necessary, to enable the settings
change. The WPC 2000 is now in Foot Trip mode, the press stroking each time the Foot
Switch is depressed.

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NOTICE
Depress the Foot Switch quickly and fully to initiate a stroke. If you depress the Foot
Switch slowly or partially, the press will not stroke.

4. Depress the Foot Switch and immediately release it. The press should make a single
stroke and stop at top dead center.

NOTICE
If the Interrupted Stroke message displays, you must depress and hold the Run/Inch
buttons on the Operator Station to bring the press back to top dead center and clear the
Interrupted Stroke before you can operate the Foot Switch.

Verify that the “FOOT N/O” item on the WPC Buttons and Switches Input Status screen
(see Figure 4-26, page 4-45) changes from an OFF to an ON status and that the “FOOT
N/C” item changes from ON to OFF.
• If the press strokes and the status of the inputs is correct, go to the next step.
• If the press does not stroke or the inputs are not in the correct state, check the wiring of
the Foot Switch, the setting of switch 3 (it should be OPEN), and the selection on the
Mode Select Menu (FOOT should be selected). Make any necessary corrections, and
repeat step 4. If the press still does not stroke, call Wintriss Tech. Support.
5. Set option switch 3 to CLOSED.
6. Power down, then power back up WPC 2000 to enable the settings change. You are now
in Foot Control mode. The press should cycle to Top-stop only if the Foot Switch is held
down past the Auto Carry-up Angle.
7. Press and hold the Foot Switch through the Auto Carry-up Angle, then release the Foot
Switch. The press should complete the stroke, stopping at Top-stop.
• If the press completes the stroke, go to the next step.
• If the press does not complete the stroke, check the wiring of the Foot Switch and the
setting of switch 3 (it should be CLOSED). Make any necessary corrections, and repeat
step 7. If the press still does not stroke, call Wintriss Tech. Support.
8. Press and hold the Foot Switch again, but release it before the Auto Carry-up Angle. The
press should begin to cycle but stop immediately when the Foot Switch is released.
• If the press stops, go to the next step.
• If the press does not stop, check the wiring of the Foot Switch, making any necessary
corrections, and repeat step 8. If the press still does not stop, call Wintriss Tech.
Support.
9. Press and hold both Run/Inch buttons to return the press to TDC.
10. Set the Stroke Select switch to “CONT.” Verify that the “CONT SEL” item on the WPC
Buttons and Switches Input Status screen shows an ON status (see Figure 4-26,
page 4-45).

Installation 2-109
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

11. Press the Prior Act button on the Operator Station, and, before the indicator lamp goes out,
depress and hold down the Foot Switch. The press should run as long as the Foot Switch
is depressed, stopping at Top-stop after completion of the stroke when the Foot Switch is
released.
• If the press behaves correctly, go to the next step.
• If the press behaves otherwise, check the wiring of the Foot Switch and Operator
Station, correcting any problems, and repeat step 11. If the press still fails to run and/or
stop correctly, call Wintriss Tech. Support.
12. Press the Prior Act button and, before the indicator lamp goes out, depress the Foot
Switch, immediately releasing it. The press should stop after a single stroke.
• If the press stops correctly, go to the next step.
• If the press does not stop correctly, check the wiring of the Foot Switch and Operator
Station, correcting any problems, and repeat step 12. If the press still fails to stop
correctly, call Wintriss Tech. Support.
13. If you want to repeat testing of the Foot Switch in Continuous mode, make sure to press
the Prior Act button before attempting to initiate another stroke.
14. Go to the next applicable test.

One-hand Control Test

! DANGER
INJURY DURING TESTING
• Keep all personnel away from the press during testing.
• Be sure there is no die or other tooling in the press during testing.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
MISSING SAFEGUARDS
Install a light curtain for use with the One-hand Control option. A light curtain is required for using
the One-hand Control.
Failure to comply with these instructions will result in death or serious injury.

This test, which should be run only if you have an optional One-hand Control, verifies that
your One-hand Control is operating properly. To perform the test, do the following, referring
to Figure 2-41 for LED locations and Input Status, page 4-44 for instructions in how to access
the Input Status screens:
1. On the SmartPAC 2 front panel:
• Make sure the Program/Run key switch is set to RUN.
• Turn the Stroke Select key switch of OFF.
• Select ONE HAND on the Mode Select Menu (see page 6-39)
• Turn the Stroke Select key switch to SINGLE STROKE.

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Verify that the “S.S. SEL” and “PALM A N/C” items on the WPC Buttons and Switches
Input Status screen are ON (see Figure 4-26, page 4-45).
2. Make sure that option switch 3 on the WPC 2000 Main Processor board is set to OPEN, its
default setting (see Enabling Light Curtain Break Mode in a One-hand Control,
page 4-36).
3. Power down, then power back up the WPC 2000, if necessary, to enable the settings
change. The WPC 2000 is now in normal One-hand Control operation, the press stroking
each time the One-hand Control switch is depressed.

NOTICE
Depress the One-hand Control switch quickly and fully to initiate a stroke. If you depress
the One-hand Control switch slowly or partially, the press will not stroke.

4. Press the One-hand Control switch and release it immediately. The press should make a
single stroke and stop at top dead center.

NOTICE
If the Interrupted Stroke message displays, you must press and hold the Run/Inch buttons
on the Operator Station to bring the press back to top dead center and clear the
Interrupted Stroke before you can operate the One-hand Control.

Verify that the “ONE HAND N/O” item on the WPC Buttons and Switches Input Status
screen (see Figure 4-26, page 4-45) changes from an OFF to an ON status when the
One-hand Control is depressed and that the “PALM A N/C” item changes from ON to
OFF.
• If the press makes a complete stroke and the status of the “ONE HAND N/O” and
“PALM A N/C” inputs is correct, go to the next step.
• If the press does not make a complete stroke or the status of the inputs is not correct,
check the wiring of the One-hand Control, the setting of switch 3 (it should be OPEN),
and the selection on the Mode Select Menu (ONE HAND should be selected). Make
any necessary corrections, and repeat step 4. If the press still fails to make a complete
stroke or input status is still incorrect, contact Wintriss Tech. Support.
5. Set option switch 3 to CLOSED.
6. Power down, then power back up WPC 2000 to enable the settings change. You are now
in Light Curtain Break mode. The press should cycle to Top-stop only if the One-hand
Control is pressed within eight seconds of the operator’s hand clearing the light curtain.
7. Without breaking the light curtain, press the One-hand Control. The press should not
cycle.
• If the press does not cycle, go to the next step.
• If the press cycles, check the wiring of the One-hand Control and the setting of switch 3
(it should be CLOSED). Make any necessary corrections, and repeat step 7. If the press
still cycles, call Wintriss Tech. Support.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

8. Now break the light curtain to activate the One-hand Control, then remove your hand and
press the One-hand Control within eight seconds. The press should make a complete
stroke, stopping at Top-stop.
• If the press cycles, go to the next step.
• If the press does not cycle, check the wiring of the One-hand Control, correcting any
problems, and repeat step 8. If the press still cycles, call Wintriss Tech. Support.
9. Break the light curtain again, but this time wait ten seconds or longer before pressing the
One-hand Control. Use a watch or timer to verify the delay interval. The press should not
make a stroke.
• If the press does not make a stroke, go to the next step.
• If the press strokes, check the wiring of the One-hand Control, correcting any problems,
and repeat step 9. If the press still makes a stroke, call Wintriss Tech. Support.
10. Go to the next applicable test.

Bar Mode Control Test

! DANGER
INJURY DURING BAR MODE TESTING
• Be sure there is no die or other tooling in the press during testing.
• Keep all personnel away from the press during testing.
• Use a spring-loaded turnover bar when you bar the press.
Failure to comply with these instructions will result in death or serious injury.

This test, which should be run only if you have an optional Bar Mode Control, verifies that
your Bar Mode Control is operating properly. To perform the test, do the following, referring
to Input Status, page 4-44 for instructions in how to access the Input Status screens:
1. On the SmartPAC 2 front panel:
• Make sure the Program/Run key switch is set to RUN.
• Turn the Stroke Select key switch of OFF.
• Select TWO HAND on the Mode Select Menu (see page 6-39).
• Turn the Stroke Select key switch to INCH.
2. Set the Select switch on the Bar Control to “ON.” Verify that the “BAR MODE” item on
the WPC Buttons and Switches Input Status screen is ON (see Figure 4-26, page 4-45).
3. Turn the press motor off.
4. While the press’s flywheel is still turning, press and release the Operate button on the Bar
Mode Control. Verify that the following events occur:
• The Dual Safety Valve should energize while the Operate button is depressed and
de-energize when the button is released
• The “BAR ACT” item on the WPC Buttons and Switches Input Status screen should
change from OFF to ON and remain ON while the Operate button is depressed

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• The F26 fault code should appear on the SmartPAC 2 display

5. Press RESET to clear the fault.
6. When the flywheel has stopped turning, press and hold the Operate button on the Bar
Mode Control. The Dual Safety Valve should energize and stay energized.
7. You can now bar the press, using a spring-loaded turnover bar.

NOTICE
As you bar the press, WPC 2000 monitors the speed of the crank. If you bar the press too
quickly, the DSV de-energizes and an F26 fault code displays, stopping the press.

8. Go to the next applicable test.

Checking Operation of the User Inputs

This test verifies that any user inputs you have connected to auxiliary press functions are
wired and operating correctly. If you have not wired any user inputs, go to the next section.
To perform this test, do the following:
1. Run the press. Actuate one of the user inputs.
• If the press stops and the appropriate fault code displays, the input is wired and
operating properly. Repeat the test for the other user inputs. When you have checked
all of the inputs, go to the next test.
• If the press does not stop and/or the appropriate fault code does not display, check the
wiring of that input, referring to Wiring WPC 2000 User Inputs, page 2-31, and rerun
the test. If the press still does not stop and/or the correct fault code does not display, call
Wintriss Tech. Support.

Checking Cam Channels (ProCamPAC Only)

Create some test settings for your cam channels in Program mode (see CAM SWITCH
(Optional), page 5-38), 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.

What Next?
To program and use your SmartPAC 2, follow the instructions in the remaining chapters of
this manual. Go to Chapter 4 to make Initialization settings for your SmartPAC 2.

Wiring Tables
Tables showing WPC 2000 and SmartPAC 2 wiring connections are provided on the
following pages.

Installation 2-113
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Table 2-27. WPC 2000 Main Processor Board, TB101-TB104: Wiring Connections
Pin Signal Pin Signal
TB104 Top TB104 Bottom
44 Analog ground 88 Light curtain B2 input **
43 Counterbalance air (Analog 2) input 87 Light curtain A2 input **
42 +24 Vdc output 86 User input 10 – (paired w/ User Input 11*)
41 +24 Vdc output 85 User input 8 – (paired w/ User Input 9*)
40 +24 Vdc output 84 User input 6 –
39 +24 Vdc output 83 User input 4 –
38 +24 Vdc output 82 User input 2 +
37 +24 Vdc output 81 Top-stop string input (connects internally to 49)
36 Aux. 2 output 80 Top-stop string center loop connection
35 Light curtain 2 enable 79 Top-stop string drive output
TB103 Top TB103 Bottom
34 Analog ground 78 Light curtain B1 input **
33 Main system air (Analog 1) input 77 Light curtain A1 input **
32 +24 Vdc output 76 Mute lamp 2 output +
31 Ground 75 Unused input –
30 Ground 74 User input 9 – (paired w/ User Input 8*)
29 Aux. 3 output 73 User input 7 –
28 Aux. 1 output 72 User input 5 –
27 Light curtain 1 enable 71 User input 3 +
26 Unused input + 70 Remote reset input –
25 Ground 69 E-stop string input (connects internally to 45)
24 Overrun limit switch input - 68 E-stop string center loop connection
23 +24 Vdc output 67 E-stop string drive output
TB102 Top TB102 Bottom
22 Top stop limit switch input – 66 Mute lamp 1 output +
21 User input 1 + 65 Palm time lamp output –
20 DSV monitor input + 64 Prior act lamp output –
19 Unused input – 63 Prior act B input +
18 User input 11 – (paired w/ User Input 10*) 62 Prior act B output
17 Motor reverse input + 61 Prior act A input (connects internally to 62)
16 Bar actuator input + 60 Top-stop B2 input + pulse
15 Auto. Single-stroke (Ext. Trip) actuator N/C + 59 Top-stop B2 output
14 Foot switch N/O input + 58 Top-stop A2 input (connects internally to 59)
13 Top Stop in Inch Disable input + 57 E-stop B2 input + pulse
12 Palm switch B N/O input + 56 E-stop B2 output
11 Palm switch A N/O input + 55 E-stop A2 input (connects internally to 56)
TB101 Top TB101 Bottom
10 Ground 54 Ground
9 +24 Vdc output 53 +24 Vdc output
8 Clutch air pressure switch input – 52 Top-stop B1 input + pulse
7 Motor forward input + 51 Top-stop B1 output
6 Bar selector switch input + 50 Top-stop A1 input (connects internally to 51)
5 Auto. Single-stroke (Ext. Trip) actuator N/O + 49 Top-stop A output
4 Foot switch N/C input + 48 E-stop B1 input + pulse
3 One hand A input + 47 E-stop B1 output
2 Palm switch B N/C input + 46 E-stop A1 input (connects internally to 47)
1 Palm switch A N/C input + 45 E-stop A output
* See Wiring WPC 2000 User Inputs, page 2-31.
** Input polarity depends on setting (NPN or PNP) of Light Curtain Output Type jumpers (JP121 and JP123) on
WPC 2000 Main Processor board (see Figure 2-14, page 2-28).

2-114 Installation
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Table 2-28. WPC 2000 Power Supply Table 2-32. SmartPAC 2 SFI Port (1)
(TB105) Wiring Connections and Module Port (2) (TB103)
Wiring Connections
Pin # Signal
90 +24 Vdc input Pin # Signal Port
89 COM 235 +RXD1 SFI PORT (1)
236 –RXD1 “
Table 2-29. WPC 2000 Aux. E-stop Relay 237 TXD1 “
Board Wiring Connections 238 +TXD1 “
Pin # Signal 239 –TXD1 “
96 Circuit 3 output 240 GND “
95 Circuit 3 input 241 +RXD2 MODULE
PORT (2)
94 Circuit 2 output
242 –RXD2 “
93 Circuit 2 input
243 +TXD2 “
92 Circuit 1 output
244 –TXD2 “
91 Circuit 1 input

Table 2-33. SmartPAC 2 Special Port (3)

Table 2-30. WPC 2000 DSV/Lockout Relay
and PACNet Port (4) (TB104)
Board Wiring Connections
Wiring Connections
Pin # Signal
Pin # Signal Port
103 DSV B relay output
224 +RXD3 SPECIAL
102 DSV B relay input PORT (3)
101 DSV A relay output 225 –RXD3 “
100 DSV A relay input 226 TXD3 “
99 Lockout relay output 227 +TXD3 “
98 Lockout relay output 228 –TXD3 “
97 Lockout relay input 229 GND “
230 +RXD4 PACNET
Table 2-31. WPC 2000 AC Power PORT (4)
Wiring Connections 231 –RXD4 “
Pin # Signal 232 TXD4 “
L1 (Hi) 233 +TXD4 “
L2 (Neutral) 234 –TXD4 “
Ground

Installation 2-115
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Table 2-34. SmartPAC 2 Spare 1 Port (5) Table 2-36. SmartPAC 2 Aux I/O (TB107)
and WPC Port (6) (TB105) Wiring Connections
Wiring Connections
Pin # Signal
Pin # Signal Port 245 +15 V
330 –TXD6 WPC PORT 246 POSITION SENSOR
(6)
247 GND
329 +TXD6 “
248 ZERO
328 –RXD6 “
249 REMOTE RESET
327 +RXD6 “
250 GND
326 GND “
251 LOCKOUT
325 –TXD5 SPARE 1
PORT (5) 252 INCH/SETUP
324 +TXD5 “ 253 OP STA 2
323 TXD5 “ 254 OP STA 1
322 –RXD5 “
321 +RXD5 “

Table 2-35. SmartPAC 2 Spare 3 Port (7)

and Spare 4 Port (8) (TB106)
Wiring Connections
Pin # Signal Port
320 –TXD8 SPARE 2
PORT (8)
319 +TXD8 “
318 TXD8 “
317 –RXD8 “
316 +RXD8 “
315 GND “
314 –TXD7 SPARE 3
PORT (7)
313 +TXD7 “
312 TXD7 “
311 –RXD7 “
310 +RXD7 “

2-116 Installation
Chapter 3. SmartPAC 2 Keyboard,
Displays and Operating Modes
This chapter shows you how to use the SmartPAC 2 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 front panel, which is shown in Figure 3-1.
It is a good idea to learn how to use SmartPAC 2 before you install it. Set up the unit on a
bench and wire a power cord and a resolver to it, then try making settings on the displays.
SmartPAC 2 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
Wintriss Press Automation Control

PRESS #14
TOOL NUMBER 6160 PART CNTR 449
CAMBIE
AL ESPANOL F1
FLANGE B TWO HAND S.S.
PRESS ANGLE 270
POWER F2

USE THE CURSOR KEYS ENABLE SENSORS

F3
BRAKE TO MAKE SELECTIONS. COUNTERS
WARNING PRESS ENTER TO
ACCESS SELECTION.
DIE PROTECTION
CAM SWITCH
F4
BRAKE MONITOR
TONNAGE/WAVEFORM
PRESS CONTROL
F5
FEED CONTROL
TOOL INFORMATION
F6
270 SHUTHGT/CNTRBAL
ERROR LOG
LOAD NEW TOOL
F7
DIALOG MENU
TOGGLE HOT KEYS 1
F8
SINGLE
INCH
STROKE
CONT 1 2 3 PROG RUN
ENTER
OFF
4 5 6
HELP

7 8 9 RESET

CLEAR
0 .

Figure 3-1. SmartPAC 2 with WPC 2000 Front Panel

This chapter covers the following topics:

• Comparing SmartPAC 2 with Original SmartPAC, next section
• SmartPAC 2 Keyboard, page 3-3
• SmartPAC 2 Display Layout in Run Mode, page 3-13
• SmartPAC 2 Operating Modes, page 3-15
• Screen Capture, page 3-23

Keyboard, Displays, Etc. 3-1

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Comparing SmartPAC 2 with Original SmartPAC

If you are familiar with the original SmartPAC, you will find using the SmartPAC 2 very
similar. Figure 3-2 shows the differences between SmartPAC 1 and SmartPAC 2 front panels.
Some of the instructions in this manual are based on those for the original SmartPAC.

SmartPAC 2 with WPC 2000 Integration Original SmartPAC with WPC Integration

Interrupted Stroke Message Crank Angle/SPM display Interrupted Stroke Indicator

SmartPAC 2 only original SmartPAC only

SmartPAC 2
TOOL NUMBER 6160 PART CNTR 0 F1
PRESS # 14
TOOL NUMBER 6160 PART CNTR 0
CAMBIE
AL ESPANOL F1 CHAIR BRACKET

FLANGE TWO HAND S.S. F2

INTERRUPTED STROKE PRESS ANGLE 330 INTERRUPTED

POWER F2 USE THE CURSOR KEYS

TO MAKE SELECTIONS.
ENABLE SENSORS
COUNTERS
F3
STROKE

PRESS ENTER TO DIE PROTECTION

Contrast ACCESS SELECTION CAM SWITCH
F3 TOOL INFORMATION
F4 BRAKE
USE THE CURSOR KEYS ENABLE SENSORS RAM POSITION WARNING
BRAKE TO MAKE SELECTIONS. COUNTERS RAM TONNAGE
WARNING PRESS ENTER TO
ACCESS SELECTION.
CAM SWITCH
BRAKE MONITOR
F4 ERROR LOG
LOAD NEW TOOL F5
PROG RUN
TONNAGE/WAVEFORM
PROCESS MONITOR
FEED CONTROL
F5 F6
PM MONITOR
TOOL INFORMATION F6
330 SHUTHGT/CNTRBAL
ERROR LOG
LOAD NEW TOOL F7
1

4
2

5
3

6
ENTER INCH

OFF
SINGLE
STROKE
CONT

DIALOG MENU
TOGGLE HOT KEYS 1 CURSOR

F8 7 8 9
RESET
SINGLE
SINGLE CLEAR 0 .
INCH
INCH
STROKE
STROKE
CONT
CONT 1 2 3 PROG RUN
ENTER
OFF
OFF
4 5 6 SmartPAC
®

HELP
Wintriss Press Automation Control
7 8 9 RESET

CLEAR
0 .
Contrast keys
original SmartPAC
only
Help key
SmartPAC 2
only 8 Function keys 6 Function keys

Figure 3-2. Differences Between SmartPAC 2 and Original SmartPAC

SmartPAC 2 and the original SmartPAC are very similar in appearance, and many of the
procedures for using them are the same. The differences between their front-panel controls
are:

Item SmartPAC 2 Original SmartPAC

Crank Angle/SPM display In the center of the Crank Angle Separate red 3-digit LED display
clock on the display and in the
status box at the top of the display.
Function Keys 8 function keys 6 function keys
Help Key At center of cursor keys; None
press to access information about
the current screen.
Contrast keys None–display is self-adjusting 2 to left of display screen
Interrupted Stroke Message flashes in status box at Indicator light on front panel
indication top of display

3-2 Keyboard, Displays, Etc.

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

SmartPAC 2 Keyboard
The SmartPAC 2 keyboard, as shown in Figure 3-3, is composed of number keys, cursor keys,
function keys, and HELP, CLEAR, ENTER, and RESET keys. There are also two key
switches: Stroke Select and Program/Run. Use of the keys and key switches is explained in
the following sections.

HELP key F1
ENTER
key F2
INCH
SINGLE
STROKE
CONT
1 2 3 PROG RUN F3
ENTER

4 5 6
OFF
F4
HELP
F5
7 8 9 RESET
F6
Stroke Select
Key Switch
CLEAR
0 . Program/Run
Key Switch F7
Cursor
keys RESET
Number keys key F8
Function
CLEAR keys
key (F keys)

Figure 3-3. SmartPAC 2 Keyboard

Stroke Select Key Switch

The Stroke Select key switch, shown in Figure 3-4, is used to select the operating mode of the
press: Off, Inch, Single-stroke, or Continuous (see page 6-38). This key switch is also used to
clear the Lockout message when it appears on the SmartPAC 2 display (see page 7-3). To do
so, turn the key to the “OFF” position, then back to the operating mode you want.
Users can be prevented from changing the operating mode by removing the key.

SmartPAC 2
F1
CAMBIE
AL ESPANOL

F2
Stroke Select
POWER

F3
BRAKE key switch
WARNING
F4
F5 SINGLE
STROKE
F6 INCH CONT
F7
OFF
F8
SINGLE
INCH
STROKE
CONT 1 2 3 PROG RUN
ENTER
OFF
4 5 6
HELP

7 8 9 RESET

CLEAR
0 .

Figure 3-4. Stroke Select Key Switch

Keyboard, Displays, Etc. 3-3

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

! DANGER
CONTINUOUS MODE USED ON PRESS NOT GUARDED PROPERLY FOR CONTINUOUS
Disconnect the “Continuous” position on the Stroke Select switch to prevent your press from being
run in Continuous mode if it is not guarded correctly for use in Continuous mode. Also cover the
“CONT” label on your control’s Stroke Select switch.
Failure to comply with these instructions will result in death or serious injury.

Number Keys
The number keys, shown in Figure 3-5, 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 screens
(see Figure 3-6, below, and Figure 3-7, page 3-5).

SmartPAC 2
F1
CAMBIE
AL ESPANOL

POWER F2 Number keys

F3
BRAKE
WARNING
F4
F5
F6
1 2 3
4 5 6
F7
F8
SINGLE
STROKE
1 2 3

7 8 9
INCH CONT PROG RUN
ENTER
OFF
4 5 6
HELP

7 8 9 RESET

0 .
CLEAR
0 .
CLEAR

Figure 3-5. Number Keys

To enter a number in an entry window, simply key in the individual digits of the number,
using the number keys, and press ENTER. The window closes when you are finished, and the
number you entered 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 3-6). The CLEAR key is used to delete entered information (see CLEAR Key, next). To
cancel a numeric entry operation, press RESET (see RESET Key, page 3-11).

Figure 3-6. Numeric Entry Window (Left); Alphabetic Entry Window (Right)

3-4 Keyboard, Displays, Etc.

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Figure 3-7. Alphanumeric Entry Window

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 3-23). 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 crankshaft angle
in large characters (see page 6-6). This window carries over to other Run mode screens on
which a prominent crankshaft 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 crankshaft angle on Main Run
Menu and selected Run mode
screens

CLEAR Key
The CLEAR key, shown in Figure 3-8, is used to delete digits or characters in a SmartPAC 2
entry window (see Figure 3-6 and Figure 3-7). You also use the CLEAR key as directed in
other procedures, such as deleting a tool.

SmartPAC 2
F1
CAMBIE
AL ESPANOL

POWER F2
F3
BRAKE
WARNING
F4
F5 CLEAR key
F6
F7
CLEAR
F8
SINGLE
INCH
STROKE
CONT 1 2 3 PROG RUN
ENTER
OFF
4 5 6
HELP

7 8 9 RESET

CLEAR
0 .

Figure 3-8. Clear Key

Keyboard, Displays, Etc. 3-5

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Cursor Keys
The cursor, or arrow, keys, shown in Figure 3-9, 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 (see page 3-23)

SmartPAC 2
CAMBIE
AL ESPANOL F1 Cursor (arrow)
POWER F2 keys
F3
BRAKE
WARNING
F4
F5
F6
F7
F8 HELP
SINGLE
INCH
STROKE
CONT 1 2 3 PROG RUN
ENTER
OFF
4 5 6
HELP

7 8 9 RESET

CLEAR
0 .

Figure 3-9. Cursor Keys

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 screen, such as the CAM SWITCH item on the SmartPAC 2 Run Menu shown in
Figure 3-10.

Figure 3-10. Highlighted Item on Run Menu

Pressing the Up () or Down () cursor key moves the highlight bar up or 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 the key down, the highlight bar moves until you release it.

3-6 Keyboard, Displays, Etc.

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 3-6 and Figure 3-7, page 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 the key down, the value continues to
increase or decrease until you release it.

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 3-6 and Figure 3-7). 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 3-7), 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 4-6.

Using Cursor Keys to Set Timing

You can use the cursor keys to set timing for your optional programmable cam switch and
sensors, setting the crankshaft angles at which you want a Ready signal or cam channel 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 (Optional), page 5-38.
Timing settings are made on a crank 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.

Keyboard, Displays, Etc. 3-7

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 crankshaft angles
are both 0°, as shown in Figure 3-11. The “dwell” (i.e., the number of degrees during
which the channel is On) is 0°.

Figure 3-11. 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 crank angle
diagram until you reach 239°. The On angle is shown in the window in the center of the
crank angle clock. Your display should look like the one shown in Figure 3-12, page 3-9.
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 crank angle clock.

NOTICE
Zero degrees (0°) and 360° are located at the same point in the crankshaft rotation.

3-8 Keyboard, Displays, Etc.

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Figure 3-12. Cam Channel Timing: On=239°, Off=0°

3. To set the Off angle, you use the Up () and Down () cursor keys. With the cam
channel timing set as in Figure 3-12, press the Down () cursor key and hold it down
until the Off cursor, moving counterclockwise, reaches 270° as shown in the window
inside the crank angle diagram. The channel timing display should look like the one
shown in Figure 3-13. If you overshoot the desired Off angle, press the Up () cursor
key to move the Off cursor clockwise.

Figure 3-13. Cam Channel Timing: On=239°, Off=270°

Keyboard, Displays, Etc. 3-9

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

HELP Key
The HELP key, shown in Figure 3-14, 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
F1
CAMBIE
AL ESPANOL
HELP key
POWER F2
F3
BRAKE
WARNING
F4
F5
F6
F7
F8 HELP
SINGLE
INCH
STROKE
CONT 1 2 3 PROG RUN
ENTER
OFF
4 5 6
HELP

7 8 9 RESET

CLEAR
0 .

Cursor (arrow)
keys

Figure 3-14. HELP Key

ENTER Key
The ENTER key, shown in Figure 3-15, is used to complete selection of an item or value on a
SmartPAC 2 display. After you have highlighted the item with the cursor keys (see Cursor
Keys, page 3-6), pressing the ENTER key displays the SmartPAC 2 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
F1
CAMBIE
AL ESPANOL

POWER F2
F3 ENTER
key
BRAKE
WARNING
F4
F5
F6
F7
ENTER
F8
SINGLE
INCH
STROKE
CONT 1 2 3 PROG RUN
ENTER
OFF
4 5 6
HELP

7 8 9 RESET

CLEAR
0 .

Figure 3-15. ENTER Key

NOTICE
SELECT = HIGHLIGHT + ENTER
When this manual instructs you to select an item, you should highlight the item and press ENTER.

3-10 Keyboard, Displays, Etc.

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

RESET Key
The RESET key, shown in Figure 3-16, 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 fault message documenting the error
disappears, and you can once again run the press.

SmartPAC 2
F1
CAMBIE
AL ESPANOL

POWER F2
F3 RESET
key
BRAKE
WARNING
F4
F5
F6
F7
RESET
F8
SINGLE
INCH
STROKE
CONT 1 2 3 PROG RUN
ENTER
OFF
4 5 6
HELP

7 8 9 RESET

CLEAR
0 .

Figure 3-16. RESET Key

Program/Run Key Switch

The Program/Run key switch, shown in Figure 3-17, is used to move between Program and
Run modes (see SmartPAC 2 Operating Modes, page 3-15).
• 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
F1
CAMBIE
AL ESPANOL

F2
Program/Run
POWER

F3
BRAKE key switch
WARNING
F4
F5
PROG RUN
F6
F7
F8
SINGLE
INCH
STROKE
CONT 1 2 3 PROG RUN
ENTER
OFF
4 5 6
HELP

7 8 9 RESET

CLEAR
0 .

Figure 3-17. Program/Run Key Switch

Keyboard, Displays, Etc. 3-11

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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.

Function Keys
The function keys, shown in Figure 3-18, are used to perform specific tasks on SmartPAC 2
screens. Located on the SmartPAC 2 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
CAMBIE
AL ESPANOL F1
F2
F2
F3
POWER

F3
BRAKE
F4
F4
WARNING

F5 Function
F6 keys
F7
F5

SINGLE
F8
F6
INCH
STROKE
CONT 1 2 3 PROG RUN

F7
ENTER
OFF
4 5 6
HELP

7 8 9
F8
RESET

CLEAR
0 .

Figure 3-18. 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 3-19, page 3-13, are function keys you program to take you
directly to screens you use frequently in Run mode. 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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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

PRESS #14
TOOL NUMBER 6160 PART CNTR 25346
CAMBIE
AL ESPANOL F1
FLANGE TWO HAND CONT
PRESS ANGLE 270 VIEW SENSOR
SUMMARY F2
VIEW GLOBAL
CAM SUMMARY F3
USE THE CURSOR KEYS ENABLE SENSORS
TO MAKE SELECTIONS. COUNTERS
PRESS ENTER TO
ACCESS SELECTION.
DIE PROTECTION
CAM SWITCH
ADJ SENSOR
PART EJECTION F4
BRAKE MONITOR Use F1 - F8 as Hot keys
TONNAGE/WAVEFORM
PRESS CONTROL
ADJUST CAM
SPRAY LUBE F5 If you have the Bilingual Option,
FEED CONTROL F1 is reserved for changing
TOOL INFORMATION TONNAGE
F6 language and cannot be used
270
PLAN VIEW
SHUTHGT/CNTRBAL
ERROR LOG as a Hot key.
LOAD NEW TOOL
DIALOG MENU
DISPLAY
SHUT HEIGHT F7
TOGGLE HOT KEYS 1
ADJUST
SETPOINTS F8

Descriptive labels
for Hot keys

Figure 3-19. 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 alternate language 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
does not have the alternate language 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 Display Layout in Run Mode

The layout of the SmartPAC 2 display in Run mode is shown in Figure 3-20, page 3-14. 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 3-12), 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.

Keyboard, Displays, Etc. 3-13

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

PRESS #14
TOOL NUMBER 6160 PART CNTR 51635
CAMBIE
AL ESPANOL F1
Status box FLANGE TWO HAND S.S.
PRESS ANGLE 270
F2
Instructions USE THE CURSOR KEYS ENABLE SENSORS
F3
TO MAKE SELECTIONS. COUNTERS
PRESS ENTER TO
ACCESS SELECTION.
DIE PROTECTION
CAM SWITCH
F4
BRAKE MONITOR
Crank Angle/SPM TONNAGE/WAVEFORM F5
readout PRESS CONTROL
FEED CONTROL
TOOL INFORMATION
F6
270 SHUTHGT/CNTRBAL
ERROR LOG
LOAD NEW TOOL
F7
DIALOG MENU
TOGGLE HOT KEYS 1
F8
Crank angle clock

Run window Menu Descriptive labels for

Function keys and Hot keys

Figure 3-20. SmartPAC 2 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 3-6), and press ENTER. Figure 3-21 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.

Figure 3-21. Main Run Menu with “CAM SWITCH” Highlighted

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 3-22 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 3-16 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, as shown in Figure 3-22. 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 black text on light green display
settings for the press settings for individual tools

Run Mode (Chapter 6)

black text on light blue display
live screens; some adjustments possible “on the fly”

Figure 3-22. SmartPAC 2 Operating Modes, Showing Main Menus

Keyboard, Displays, Etc. 3-15

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Table 3-2. Initialization, Program and Run Modes: Entry and Exit Procedures

Mode How to Enter This Mode How to Exit This Mode

Initialization Turn Program/Run key to To switch to Program mode:
PROG.* Then press the “1”
Make settings that control Press RESET.
and “CLEAR” keys
operation of SmartPAC 2 with
simultaneously and hold down _______________________
all tools. a few seconds until the Main
You use Initialization mode Initialization Menu appears. To switch to Run mode:
extensively when you install a Turn the Program/Run key to
new SmartPAC 2. You will use RUN.*
this mode only occasionally
after you set up SmartPAC 2
and the press is running.
See page 3-17 and Chapter 4.
White text on dark blue display.
Program From Run mode: To switch to Run mode:
Create, modify and load Turn the Program/Run key to Turn the Program/Run key to
settings for individual tools that PROG.* RUN.*
control SmartPAC 2 operation
_________________________ _________________________
when that tool is loaded.
To switch to Initialization mode:
See page 3-19 and Chapter 5. From Initialization mode:
Black text on light green Press the “1” and “CLEAR”
Go to the Main Initialization keys simultaneously and hold
display.
Menu, and down a few seconds until the
Press RESET. Main Initialization Menu
appears.
—or—
Turn the Program/Run key to
RUN and then back to PROG.*
Run Turn the Program/Run key to To switch to Program mode:
RUN.*
Run the press. In this mode Turn the Program/Run key to
you can adjust counters, cams, PROG.*
sensors and other functions
while the press is running.
See page 3-21 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.
If the message “PRESS CONTROL IS IN LOCKOUT MODE” appears on the SmartPAC 2 display, turn the Stroke
Select key switch to “OFF,” then back to the desired operating mode to clear the message.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 3-19.)
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 3-23. Figure 3-24, page 3-18 shows you
how to navigate through the SmartPAC 2 menus in Initialization mode.

Figure 3-23. Initialization Mode Main Menu

See Chapter 4 for detailed instructions on how to use SmartPAC 2 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 PROGRAM ON/OFF ANGLES

INITIALIZATION MODE MAIN MENU RESOLVER MOTION MODE PROGRAM TIMED OUTPUT

RESOLVER ZERO ANGLE WHEEL ROTATION PROGRAM AUTO ADVANCE

POSITION SENSOR TOOL NUMBER MODE PROGRAM DSV ON

INSTALLED OPTIONS COUNTER SETUP MODE DELETE CHANNEL SETTINGS

PRESS NAME select input

SELECT CAM NAMES select channel
F2 - CALIBRATE
AUTO ADVANCE F5 - VIEW GLOBAL CAM SUMMARY
F3 - SHOW CALFACTORS
SET GLOBAL CAMS F4 - ZERO OFFSETS
CUSTOM SENSOR NAMES SENSOR ENABLE MODE
SETUP MODE UPPER LIMIT
SENSOR ENABLE MODE
LOWER LIMIT
TONNAGE/WAVEFORM
STOP ADVANCE
RAMPAC INIT SET INPUT NAMES
UPPER TOL (+)
FEED CONTROL SET PRESS CAPACITY
LOWER TOL (-)
TOOL INFORMATION CALIBRATION
UNITS TYPE
PRESS CONTROL LOW SETPOINT
BALL SOCKET
SECURITY ACCESS REPEATABILITY SETPOINT
F3 - CHANGE UNITS
BACKUP/RESTORE SETUP MODE
F4 - SAVE UPPER LIMIT
SETUP DATA COMMS STARTUP COUNTER
F5 - SAVE LOWER LIMIT
SETUP NETWORK SET REVERSE SETPOINT %
LUBE/SPEED/FLYWBRAKE SET PRESS PARAMETERS F2 - BUTTONS/SWITCHES
DIAGNOSTICS INITIALIZE PARAMETERS F3 - ESTOPS/TOP STOPS
F4 - INTERLOCKS
SHUT HEIGHT CONTROL ENABLE
RSR/SBR CPU NUMBER
COUNTERBALANCE CONTROL ENABLE
FORCED IDLE DIALOG
CUSHION CONTROL ENABLE
IDLE DIALOG TIME
INITIALIZE PARAMETERS
FORCED ERROR DIALOG
F3 - SHUT HEIGHT SETUP
ERROR DIALOG TIME
F4 - COUNTERBALANCE SETUP
PERSIST DIALOG
F5 - CUSHION SETUP
DIALOG RESET STROKES
SINGLE STOKE MODE
USER INTERLOCKS
IDLE TIMER
PRESS PARAMETERS
SET SPECIAL NAMES
PRESS OPTIONS SET CANNED NAMES
INPUT STATUS
RESOLVER
COMMUNICATIONS
set access privileges
INPUT STATUS
F1 - CHANGE PASSWORDS
ANALOG STATUS
OUTPUT STATUS

E-MAIL FUNCTION SET CLOCK

SMARTVIEW FUNCTION MEMORY CHECKSUM

SET UP E-MAIL TOOL TABLES

CHANGE NETWORK SETTINGS CLEAR TABLES

PRESS TYPE SHOW SBC ERRORS

menu item SAVE TO USB DISK
Function Key UPDATE FIRMWARE

Figure 3-24. 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.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Program Mode
Program mode allows you to create, copy, modify and delete tools as well as enable or disable
sensors. The Main Program Menu is shown in Figure 3-25. Figure 3-26, page 3-20 shows
you how to navigate through the SmartPAC 2 menus in Program mode.

Figure 3-25. Program Mode Main Menu

See Chapter 5 for detailed instructions on how to use SmartPAC 2 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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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 ID BATCH 1 PRE-LOAD COUNT
COUNTERS BATCH 2 PRE-LOAD COUNT
DIE PROTECTION BATCH 3 PRE-LOAD COUNT
CAM SWITCH AUTO BATCH PRE-LOAD
TONNAGE/WAVEFORM
SHUTHGT/CNTRBAL AUTO ENABLE COUNTER

PRESS CONTROL select sensor

TOOL INFORMATION F6 - VIEW SENSOR SUMMARY

F5 - LOAD THIS TOOL

SENSOR NAME
SENSOR TYPE
PROGRAM MODE MAIN MENU F4 - EDIT TOOL
STOP TYPE
select F5 - LOAD TOOL
GO TO THE TOOL MANAGER READY WINDOW
tool F6 - DELETE TOOL
SENSOR ENABLE/DISABLE & STATUS F7 - NEW TOOL
RECALCULATE SETPOINTS F8 - COPY TOOL select cam channel
F5 - VIEW GLOBAL CAM SUMMARY
SENSOR ON/OFF STATUS
F6 - VIEW CAM SUMMARY

TOP STOP ANGLE PROGRAM ON/OFF ANGLES

CONTINUOUS SPEED PROGRAM TIMED OUTPUT
MAXIMUM PRESS SPEED PROGRAM AUTO ADVANCE
MAXIMUM PRESS SPEED PROGRAM DSV ON
CNTR BAL SETPOINT DELETE CHANNEL SETTINGS

HIGH PERCENTAGE
COUNTERBALANCE MODE
LOW PERCENTAGE
MAX UPPER DIE WEIGHT
REPEATABILITY %
UPPER DIE WEIGHT
SAMPLE PERIOD
CUSHION MODE
menu item CUSHION PRESSURE OPERATING MODE

Function Key SHUT HEIGHT F6 - SHOW WAVEFORMS

F4 - SAVE THE SHUT HEIGHT

Figure 3-26. 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.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Run Mode
Run mode is the mode you use to run the press. The Main Run Menu, shown in Figure 3-27,
displays the rotation of the crankshaft on a crank 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 crankshaft angle is displayed inside the clock.
If security access settings in Program mode permit, you may be able to adjust cam timing and
perform other operations in Run mode (see CAM SWITCH (Optional), page 6-18).
Figure 3-28, page 3-22 shows you how to navigate through the SmartPAC 2 menus in Run
mode.

Figure 3-27. Run Mode Main Menu

See Chapter 6 for detailed instructions on how to use SmartPAC 2 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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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

CURRENT TO STORED WAVEFORM

CURRENT TO HELD WAVEFORM
HELD TO STORED WAVEFORM
F6 - VIEW SENSOR SUMMARY CURRENT TO CRITICAL CURVE
RUN MODE MAIN MENU F7 - SHOW SENSOR STATUS SET THE PRESS STROKES/MIN
ENABLE SENSORS
COUNTERS F5 - VIEW GLOBAL CAM SUMMARY F1 - DISPLAY SELECT
DIE PROTECTION F6 - VIEW CAM SUMMARY F3 - UPDATE WAVEFORMS
CAM SWITCH F7 - SHOW CAM TIMING F4 - COMPARE WAVEFORMS
BRAKE MONITOR F5 - STORE/HOLD WAVEFORMS
TONNAGE/WAVEFORM SHOW WAVEFORMS
PROCESS MONITOR SHOW “PLAN” VIEW
PRESS CONTROL SHOW BARGRAPHS F5 - RESCALE THE GRAPH
TOOL INFORMATION ADJUST SETPOINTS
SHUTHGT/CNTRBAL TONNAGE HISTORY F2 - HIGH SETPOINT
ERROR/EVENT LOG RECALCULATE SETPOINTS F3 - LOW SETPOINT
LOAD NEW TOOL SHOW REVERSE TONNAGE F4 - REP SETPOINT
MESSAGING F5 - SAMPLE PERIOD
DIALOG MENU TOP STOP ANGLE F6 - RECALC SETPOINTS
TOGGLE HOT KEYS 1 MAX. PRESS SPEED
MIN. PRESS SPEED INPUT 1 = LEFT REAR
CNTR. BAL SETPOINT INPUT 2 = RIGHT REAR
F3 - SHOW OVERRUN ANGLES INPUT 3 = LEFT FRONT
INPUT 4 = RIGHT FRONT
F7 - SAVE CURRENT SHUT HEIGHT TOTAL TONNAGE
menu item
Function Key F5 - LOAD TOOL

Figure 3-28. 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.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 4-9.)
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 3-25.

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 E-2). 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 E-14).
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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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 6-36 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 6-33) 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 2-25, page 2-51),
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 4-40, page 4-61) 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
nnnnnnn is the serial number of the SmartPAC 2. The screen capture itself is named
ScreenCapturennnnnnnn.gif. There are additional files in the UpLoad folder.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 2-25, page 2-51),
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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3-26 Keyboard, Displays, Etc.

Chapter 4. SmartPAC 2 Initialization Mode
NOTICE
INITIALIZE WPC 2000 PARAMETERS BEFORE PROGRAMMING SMARTPAC 2/WPC 2000
You should already have initialized press parameters when you set up your new SmartPAC 2 with
WPC 2000 (see page 2-75). If you haven’t, do so now, following the instructions starting on
page 4-34. You must also initialize parameters when you install new WPC 2000 firmware.

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 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 zeroing the resolver, disabling the position sensor, making auto
advance settings, documenting selected information for each tool, setting up the press control,
controlling security access, backing up and restoring tool setups, setting communications
parameters, and other operations. The chapter also covers programmable cam and die
protection functions 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.

Initialization Mode 4-1

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 to enter and exit Initialization mode. See
Figure 3-24, page 3-18 for help in navigating in Initialization mode.

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
Press RESET.
simultaneously and hold down a few
seconds until the Main Initialization Menu ____________________________________
appears.
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.
If the message “PRESS CONTROL IS IN LOCKOUT MODE” displays on the SmartPAC 2 front panel, turn
the Stroke Select key switch to OFF, then back to the desired operating mode to clear the message.

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 with ProCamPAC and 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 4-64.

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Initializing WPC 2000 Parameters

NOTICE
Initializing press control parameters resets them to their default values. Initialize press parameters
only when you set up a new SmartPAC 2 with WPC 2000 or install new WPC 2000 firmware.

NOTICE
RECORD WPC 2000 SETTINGS BEFORE INITIALIZING PARAMETERS
Use the Press Parameters Setup Sheet at the end of the manual to record your WPC 2000
settings before installing new firmware or initializing parameters.

When you first set up your SmartPAC 2 with WPC 2000 or install new WPC 2000 firmware,
initialize press parameters, following the instructions provided starting on page 4-34.

RESOLVER ZERO
(INITIALIZATION – RESOLVER ZERO)
This item enables you to zero the resolver. You must zero the resolver when you first install
SmartPAC 2 (see page 2-78) and whenever you replace the resolver. Zeroing the resolver
ensures that SmartPAC 2 maintains an accurate “zero” resolver position (i.e., as close to TDC
as possible) by which it can time all its operations.
The ram must be at top dead center (TDC) when zeroing the resolver. If the ram is already at
TDC, perform the Setting the Resolver Zero Position procedure, page 4-4. Otherwise, first
inch the ram to TDC, following the Moving the Ram to Top Dead Center (TDC) procedure,
next. Then perform the Setting the Resolver Zero Position procedure.

Moving the Ram to Top Dead Center (TDC)

If the ram is not at TDC, you must first inch the press to 0° ± 2° before you can zero the
resolver. You must load a tool in order to inch the press. To move the ram to TDC, do the
following:

NOTICE
• If you turn the Program/Run key switch and nothing happens, press RESET repeatedly until the
screen changes color, indicating that the SmartPAC 2 has changed to the mode you selected.
• If the message “PRESS CONTROL IS IN LOCKOUT MODE” is displayed on the screen, turn
the Stroke Select key switch to OFF, then to one of the other operating modes to clear it.

1. With a “test” tool loaded (see Creating and Loading a Test Tool procedure, page 2-76),
turn the Program/Run key to RUN, and inch the press to 0° ± 2°.

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NOTICE
USE A DIAL INDICATOR TO DETERMINE TDC
Do not rely on the SmartPAC 2 display to indicate when the press has reached TDC. Until
the resolver is zeroed, displayed values are inaccurate. Use a dial indicator or some other
means to determine 0°.

2. When the press is at TDC, perform the next procedure.

Setting the Resolver Zero Position

To zero the resolver with the press at TDC, perform the following steps:
1. Select RESOLVER ZERO on the Main Initialization Menu. The screen shown in
Figure 4-2 displays.
The value shown in the CURRENT RESOLVER ANGLE field, which is the actual
angular position of the resolver shaft, should be as close as possible to 0°. Ideally, the
reading should be between 355° and 5°, but anywhere between 330° and 30° is acceptable.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 4-2. “Resolver Zero” Screen

2. If the current resolver angle is outside the range of 330° to 30°, loosen the tension on your
drive mechanism and turn the resolver shaft by hand (either direction is acceptable) until
the arrow on the shaft is aligned with the keyway (see Figure 2-13, page 2-26), indicating
a resolver position of 0°. Continue to adjust the position of the resolver shaft until the
reading in the CURRENT RESOLVER ANGLE field is as close to 0° as you can get it.
Then tighten the drive mechanism, making sure not to change the resolver angle reading.
3. Press the F1 (Set Resolver Zero Position) key on the Resolver Zero screen.
SmartPAC 2 electronically adds or subtracts the offset (i.e., the difference between the
CURRENT RESOLVER ANGLE reading and 0°), and the CURRENT ZERO

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CORRECTION reading should change to match the value shown in the CURRENT
RESOLVER ANGLE field.
4. Press RESET when you are finished. You are returned to the Main Initialization Menu.

POSITION SENSOR
(INITIALIZATION – POSITION SENSOR)

NOTICE
DISABLE POSITION SENSOR ON SMARPAC 2 WITH WPC 2000 INTEGRATION
An overrun limit sensor is required for SmartPAC 2 with WPC 2000 Integration (see page 2-29).
You cannot use a position sensor. Make sure to disable the POSITION SENSOR MODE setting as
instructed below.

This item allows you to disable the position sensor, 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 4-3. The following sections show you how to set each parameter

Figure 4-3. Position Sensor Screen

Position Sensor Mode

(INITIALIZATION – POSITION SENSOR)
To operate SmartPAC 2 with WPC 2000, you must disable the POSITION SENSOR MODE
setting. To do so, follow these instructions:
1. With the cursor resting on the POSITION SENSOR MODE field, press ENTER until the
“DISABLED” entry displays.
2. Press RESET to save your setting and return to the Main Initialization Menu.

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Resolver Motion Mode (Normal Motion – Link Motion)

(INITIALIZATION – POSITION SENSOR)
This item controls whether SmartPAC 2 adapts to the action of a link-motion press. The
default setting is “NORMAL MOTION.” If your SmartPAC 2 is installed on a link-motion
press, go to Using SmartPAC 2 with a Link-motion Press, page 4-65 for instructions.

Angle Wheel Rotation (Clockwise – Counterclockwise)

(INITIALIZATION – POSITION SENSOR)
This setting controls the rotational direction of the crank angle clock on the SmartPAC 2
display. The default setting is “CW DIRECTION” (Clockwise). If you want the crank angle
clock to rotate in a counterclockwise direction, press ENTER with the ANGLE WHEEL
ROTATION item selected and “CW DIRECTION” displayed. The setting changes to “CCW
DIRECTION.”

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.

NOTICE
UPGRADING FROM ORIGINAL SMARTPAC
See When You Upgrade from an Original SmartPAC, page 4-7 and Appendix F for more
information about managing tool number mode when upgrading from original SmartPAC to
SmartPAC 2.

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,
page 4-7.

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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 Automatically assigned by SmartPAC 2; assigned
Alphanumeric (letters, numbers and symbols) 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.

When You Upgrade from an Original SmartPAC

NOTICE
UPGRADING FROM ORIGINAL SMARTPAC
See Appendix F for more information about upgrading from original SmartPAC to SmartPAC 2.

When you replace an original SmartPAC with SmartPAC 2 and transfer tool setup
information, the existing tools will default to Numeric mode. If you want to switch to
Alphanumeric mode, you must perform the following procedure before you change the tool
number mode:
1. In SmartPAC 1, check to make sure that each tool has a valid, unique tool name. This will
become its alphanumeric tool number after you change tool number mode to
Alphanumeric.
2. If a tool does not have a tool name, go to Program mode and enter a unique name for it.
3. If more than one tool has the same name, change the duplicate name or names to unique
ones.
When you have completed these changes, you can set tool number mode to Alphanumeric.

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Counter Setup Mode

(INITIALIZATION – POSITION SENSOR)
This item allows you to enable or disable counter setup mode. To set this parameter, do the
following:
1. Press ENTER to toggle between three 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 INCH MODE”–The Parts counter and batch counters
whose increment mode is programmed as GOOD PARTS will not increment when you
are in Inch mode.
• “NOT INCREMENTED IN INCH MODE OR INT. STROKE MODE”–The Parts
counter and batch counters whose increment mode is programmed as GOOD PARTS
will not increment when you are in Inch mode or when there is an Interrupted Stroke.

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 H) and LETS (see Appendix I)
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.

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INSTALLED OPTIONS
(INITIALIZATION – INSTALLED OPTIONS)
This item enables you to view the options that are installed on your SmartPAC 2 (see
Figure 4-4), including the number of cam channels and sensors.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 4-4. Installed Options Screen

Your screen will look different.

If you have ordered the alternate language option, this screen provides a function key, F3
(Select Language), that allows you to select the language in which SmartPAC 2 screens are
displayed. When you press F3, the screen shown in Figure 4-5 displays.

Figure 4-5. 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 4-68.

This item enables you to name the press on which SmartPAC 2 is installed. When you select
PRESS NAME, the Alphabetic Entry window opens (see Figure 4-6), allowing you to enter
the characters composing the press name you want, using any combination of alphabetic
characters, numbers and symbols.

Figure 4-6. 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 (Optional)

(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, which appears on the Main Initialization Menu only if your SmartPAC 2 is
equipped with ProCamPAC, allows you to assign descriptive names to each of your cam
channels. You can name up to 16 channels, depending on your SmartPAC 2 configuration
(i.e., 8-channel or 16-channel ProCamPAC). Do the following to assign cam channel names:

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1. Select SELECT CAM NAMES on the Main Initialization Menu. The Cam Channel Name
Menu, shown in Figure 4-7, displays. The first time you access this screen, all channels
have the entry “UNNAMED.”

Figure 4-7. Cam Channel Name Menu (16-Channel ProCamPAC)

Your display may look different.

2. Select a channel. The screen shown in Figure 4-8 displays.

Figure 4-8. 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 seems 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 4-6, page 4-10) displays.

NOTICE
You can use a separate computer keyboard to enter cam channel names. See page 4-68.

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.

AUTO ADVANCE and Slow RPM (Optional)

(INITIALIZATION – AUTO ADVANCE)
This item, which appears on the Main Initialization Menu only when ProCamPAC is installed,
enables you to set parameters that control the timing for up to two cam channels that are
programmed as Auto Advance. You make these settings on the Auto Advance Menu (see
Figure 4-9), which displays when you select the AUTO ADVANCE item.

Figure 4-9. Auto Advance Menu

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Auto Advance is a ProCamPAC feature that allows you to provide accurate timing for
speed-sensitive functions on variable speed presses, such as feed advance, pilot release,
advance slide, part lube, and conveyors. Auto Advance works best on presses with speed
ranges from several hundred to over a thousand Strokes-per-Minute (SPM).
A channel programmed as Auto Advance automatically advances cam timing as the speed of
the press increases and delays the timing as speed decreases. The rate of advance or delay is
controlled by an advance constant, a specified number of degrees of advance for each 100
SPM increase in press speed.
You can set two advance constants on the Auto Advance Menu. Advance Constant 1 is
applied to the lowest numbered cam channel programmed as Auto Advance. Advance
Constant 2 is applied to the next lowest numbered Auto Advance channel.

NOTICE
LIMIT ON CAM CHANNEL AUTO OUTPUT SETTINGS
You cannot program more than two cam channels as Auto Advance. See Making an Auto
Advance Setting, page 5-44.

You must also specify the minimum press speed at which auto advance will be applied. This
value is entered in the SLOW RPM field on the Auto Advance Menu.

NOTICE
IMPORTANT TO SET SLOW RPM
SmartPAC 2 uses the Slow RPM value as a starting point in the auto advance process. If the
value you enter for Slow RPM is inaccurate, SmartPAC 2 will not auto advance programmed cam
channels at the right time.

The Auto Advance Menu allows you to adjust your Auto Advance and Slow RPM settings
while the press is running. When the press is stroking, the press speed in SPM is displayed in
the upper right corner of the screen under the caption PRESS SPEED. When an Auto
Advance cam is turned on, the press angle is displayed in the same location under the caption
PRESS ANGLE (see Figure 4-9). The PRESS ANGLE display enables you to see the effect
of different Advance Constant and Slow RPM settings.

Calculating the Auto Advance Constant

To calculate the auto advance constant for a specified cam channel, follow these steps:
1. Determine the fastest speed (RPMa) of your press and the angle at which the cam should
turn on at this speed (Aa).
2. Determine the slowest speed (RPMb) of your press and the angle at which the cam should
turn on at this speed (Ab).

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NOTICE
If either stopping angle occurs after 0° (or 360°), then add 360° to the angle. For instance,
if the press stops at 12°, the stopping angle is actually 12°+360° or 372°.

3. Subtract the two angle values. We will call this result “Ac.”
Aa – Ab = Ac
4. Subtract the two press speeds. We will call this result “RPMc.”
RPMa – RPMb = RPMc
5. Divide Ac (the difference between the angles) by RPMc (the difference between the press
speeds), and multiply that value by 100. This is the number of degrees per 100 RPM.
Ac / RPMc x 100 = #° / 100 RPM
Example: Calculating the Auto Advance Constant for a Pilot Release Cam
Your slowest speed is 50 RPM and the pilot release angle at that speed is 100°.
Your fastest speed is 100 RPM and the pilot release angle at that speed is 75°.
Subtract 50 RPM from 100 RPM: 100 – 50 = 50
Subtract 75° from 100°: 100 – 75 = 25
Divide the difference in angles by the difference in RPM, and multiply this by 100:
25 / 50 x 100 = 50
Your advance constant is 50° / 100 RPM.

Setting Auto Advance Constants and Slow RPM

To set the auto advance constants and slow RPM value, do the following:
1. Select AUTO ADVANCE on the Main Initialization Menu to access the Auto Advance
Menu (see Figure 4-9).
2. With the highlight bar on ADVANCE CONST. 1, press ENTER. The Numeric Entry
window (see Figure 3-6, page 3-4) displays.
3. Key in a value (maximum is 500) in the Numeric Entry window, using the numeric keypad
or the Up () and Down () cursor keys, then press ENTER.
4. Repeat steps 2 and 3 for ADVANCE CONST. 2 (maximum value is 500) and SLOW RPM
(maximum value is 2000).
5. When you are done, press RESET to return to the Main Initialization Menu.

NOTICE
AUTO ADVANCE IS ADJUSTABLE
SmartPAC 2 allows you to adjust Auto Advance and Slow RPM settings in Initialization
mode while the press is running. The angle at which an Auto Advance cam turns on is
shown in the upper right corner of the screen under the caption PRESS ANGLE, enabling
you to see the effect of different settings.

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SET GLOBAL CAMS (Optional)

(INITIALIZATION – SET GLOBAL CAMS)

! DANGER
PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE
Use SmartPAC 2’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 clutch/brake control or 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
You can use a “global” cam with the mechanical cam switch for Top Stop, if one has been installed,
to assist in adjusting top-stop and to use the Auto Advance feature to mimic Auto-compensated
Top Stop (ACTS). See Setting the ACTS Angle (Optional), page 4-33 and Switch 4 – Enabling
Auto Compensated Top Stop (ACTS), page 4-37.

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.

This item, which appears on the Main Initialization Menu only when ProCamPAC is installed,
allows you to make settings for selected cam channels that apply to all tools programmed on
your SmartPAC 2. These cam channels are called “global” cams, and they are used to
program events that remain the same on all tools. Setting global cams saves programming the
same cam information for each tool 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 (Optional), page 4-10.

1. Select SET GLOBAL CAMS on the Main Initialization Menu. The Global Cams menu,
shown in Figure 4-10, page 4-16, displays. An asterisk (*) indicates the channels that are
already programmed as global cams.

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F1
F2
F3
F4
F5
F6
F7
F8

Figure 4-10. Global Cams Menu

Asterisk (*) Indicates Global Cams

2. Select the cam you want to program. The Global Cam Timing Type screen, shown in
Figure 4-11 displays.

Figure 4-11. Global Cam Timing Type Screen

3. Select the type of cam timing you want to program for this channel, referring to CAM
SWITCH (Optional), page 5-38 for instructions.
4. When you have finished programming the global cam, press RESET.

NOTICE
If you set or change global cams while a tool is loaded, you must reload the tool to make the global
cams take effect.

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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 4-12.

NOTICE
You can use a separate computer keyboard to enter custom sensor names. See page 4-68.

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 5-22 for instructions in assigning custom names to sensors.

Figure 4-12. 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 4-6, page 4-10) 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

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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. You make these settings on the
Die Protection Mode Selection Menu (see Figure 4-13).

Pressing ENTER toggles to

AUTO BY TOOL
AUTO BY SENSOR

Figure 4-13. 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 6-6).
• 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).

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• 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 5-23).
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 4-13).
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.

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 one of two settings:
• IN INCH. Press operates in Setup mode whenever the Stroke Select switch is set to INCH
• IN INCH/INT.STRK. Press operates in Setup mode whenever the Stroke Select switch is
set to INCH or an Interrupt Stroke occurs
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 one of the other settings (i.e., IN
INCH or IN INCH/INT.STRK).
4. 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 5-50
and TOOL INFORMATION, page 6-32)

NOTICE
Tool Information screens only maintain information about the tool. They do not control any aspect
of press operation.

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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:
1. Select TOOL INFORMATION on the Main Initialization Menu. The Tool Information
Setup screen, shown in Figure 4-14, displays.

Figure 4-14. Tool Information Setup Screen

2. Highlight the NAME 1 item, and press ENTER. The Tool Information Name screen,
shown in Figure 4-15, displays.

Figure 4-15. 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.

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4. If you want to use a name that is not in the list, select the “CUSTOM” item.
5. When the Alphabetic Entry window (see Figure 4-6, page 4-10) 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 4-68.

6. Highlight the UNS 1 item, and press ENTER. The Tool Information Units Selection
screen, shown in Figure 4-16, displays.

Figure 4-16. 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 4-3, page 4-22 for an explanation of abbreviations.) You
are returned to the Tool Information Setup screen with your Units selection displayed.
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.

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Table 4-3. Abbreviations for Units on Tool Information Setup Screen

On-screen Units On-screen Units
Abbreviation Abbreviation
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

9. Highlight the zero (0) on the first line in the PLACES column, and press ENTER. When
the Numeric Entry window displays (see Figure 3-6, page 3-4), 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 4-4 provides additional information about
decimal place formats.

Table 4-4. Decimal Places and Formats

No. of Example Digits to Left of Digits to Right of Range
Places Decimal Point Decimal Point
0 Whole numbers: press speed Up to seven (7) None (0) 0 to
(SPM) 9,999,999
1 Up to five (5) One (1) 0.0 to
99,999.9
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 Up to two (2) Four (4) 0.0000 to
thickness 99.9999
8 Yes or No designation Not applicable Not applicable NO (0)
YES (1)

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.

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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 4-17.

Figure 4-17. Tool Information Setup Screen with Sample Entries

11. When you are finished, press RESET to return to the Main Initialization Menu.

PRESS CONTROL
(INITIALIZATION – PRESS CONTROL)
The PRESS CONTROL item on the Main Initialization Menu gives you access to the WPC
Initialization Menu (see Figure 4-18), which allows you to make settings specific to the WPC
2000 clutch/brake control.

Figure 4-18. WPC Initialization Menu

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

User Interlocks

(INITIALIZATION – PRESS CONTROL – USER INTERLOCKS)

! DANGER
USER INPUTS 1 THROUGH 7 NOT SUITABLE FOR SAFETY USE
DO NOT use inputs 1 through 7 as part of any personnel-protection system. These inputs are not
control reliable.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
INPUT PAIRS 8 & 9 AND 10 & 11 ARE CONTROL RELIABLE ONLY IF WIRED CORRECTLY
User input pairs 8/9 and 10/11 are control reliable only if wired correctly in a pair according to the
instructions in this section.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
USER INPUTS ADD DELAY TO STOPPING TIME
DO NOT connect light curtains or other presence-sensing devices to any user inputs. The
cross-checked input pairs (8/9 and 10/11), though control reliable, are suitable only for applications
such as connecting to safety switches used with interlocking barrier guards.
Failure to comply with these instructions will result in death or serious injury.

The USER INTERLOCKS item on the WPC Initialization Menu gives you access to the Press
Control User Interlock Menu (see Figure 4-19), on which you can set the stop type and input
name for WPC 2000’s eleven user inputs.

Figure 4-19. Press Control User Interlock Menu

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These eleven inputs are used to connect signals from other equipment in order to monitor
auxiliary press functions such as lubrication systems. Two input pairs are cross-checked so
they are control reliable when wired correctly to safety devices and can be used to connect
equipment such as interlocked barrier guards.
When one of these inputs issues a Stop command by opening a normally closed (N/C) relay, a
fault code for the input appears on the SmartPAC 2 display. The type of stop is determined by
the setting you make on this screen. For inputs 1 through 7, you can set the stop type to
E-stop, Top-stop, or E-stop/Lockout. If you have SmartPAC 2 firmware version 3.32 or
higher and WPC 2000 firmware version 1.70 or higher, an additional stop type option,
Top-stop/Lockout, is available for these inputs. If you do not want to use one of these inputs,
select “UNUSED.”
Cross-checked input pair 8/9 is programmable for E-stop or E-stop/Lockout. Cross-checked
pair 10/11 is set to E-stop/Lockout and cannot be changed. These input pairs cause WPC
2000 to E-stop the press and generate errors when one or both inputs in a pair are open or the
inputs in a pair “disagree” for longer than 100 msec. (i.e., one input is open and the other is
closed).
Input pairs 8/9 and 10/11 are always activated and cannot be turned off. If you do not want to
use one or both pairs of inputs, leave them wired to ground, as indicated in Table 2-6.
As a help to troubleshooting and installation, you can also display the status of the interlocks
by selecting the INPUT STATUS item on the WPC Initialization menu (see page 4-44).
You can connect additional equipment to your WPC 2000 by purchasing the WPC 2000
Option 1 “daughter” board, which you install on the WPC 2000 Main Processor board. The
Option 1 board provides up to 20 additional non-control-reliable user inputs and up to 4
additional control-reliable, cross-checked user inputs. See Appendix J for details. If you are
interested in this product, contact your local Wintriss representative or call Wintriss Tech.
Support.
To set the stop type and input name for each of the user inputs, do the following:

NOTICE
Input pair 8 & 9 operates as only as E STOP or E LOC. Input pair 10 & 11 operates only as E LOC.
If you set the stop type for one of these inputs to UNUSED or T STOP, SmartPAC sets it back to E
STOP or E LOC when you exit the User Interlock menu.

1. On the WPC Initialization Menu, select USER INTERLOCKS. The Press Control User
Interlock Menu displays.

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2. Highlight the stop type for the input you want to program. Press ENTER to change the
stop type. User Inputs 1 – 7 can be set to UNUSED, T STOP, E STOP or E LOC. Cross-
checked pair 8/9 can be set to E STOP or E LOC, cross-checked pair 10/11 to E LOC only.

NOTICE
If you have SmartPAC 2 firmware version 3.32 or higher and WPC 2000 firmware version
1.70 or higher, an additional stop type option, T LOC (Top-stop/Lockout), is available for
inputs 1-7.

3. Use the Right () cursor key to move the highlight bar to the input’s name
(“UNNAMED” until you select another name). Press ENTER. The Select Stop Name
screen (see Figure 4-20) displays.

Figure 4-20. Select Stop Name Screen

4. Highlight the name you want, using the cursor keys, and press ENTER. You are returned
to the Press Control User Interlock Menu with the name you selected displayed in the
right-hand column next to the appropriate user input.

NOTICE
The name you enter for input 8 is applied to both inputs 8 and 9 in the cross-checked pair.
The name you enter for input 10 is applied to both cross-checked inputs 10 and 11. Once
you have established names for inputs 8 and 10, any name you attempt to enter for input
9 or 11 will be disregarded.

If you want to enter a name that does not appear in the list, select “CUSTOM” NAME,
and when the Alphabetic Entry window displays (see Figure 4-6, page 4-10), key in the
name, following the directions in the window, then press F6 to accept your entry. You are
returned to the Select Stop Name screen.
If you are not using the input, select UNUSED.

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To access a name beneath the MORE NAMES indicator, move the highlight bar down past
the last item in the list. Additional Custom Name entries display sequentially, one at a
time.
5. Repeat steps 2 through 4 for the other user inputs.
6. When you are finished, press RESET twice to return to the Main Initialization Menu.

Press Parameters
(INITIALIZATION – PRESS CONTROL – PRESS PARAMETERS)
The Press Parameters item on the WPC Initialization Menu gives you access to the Press
Control Parameter Menu (see Figure 4-21), on which you can make the following WPC 2000
settings:
• Top-stop Angle
• Auto Carry-up Angle
• Micro-inch Time and Angle
• Main Air Pressure Limit and Counterbalance Air Pressure Offset
• Stop-time Limit
• Start-time Limit
• Shutdown Time
• Flywheel Timer
• ACTS Angle
You can also select the units that are used to display pressure on this and other Press Control
screens and instruct WPC 2000 to perform an Initialize Parameters operation.

Figure 4-21. Press Control Parameter Menu

To set any of the bulleted items shown above, perform the following steps:
1. On the Press Control Parameter Menu, move the highlight bar to the item you want, using
the cursor keys, and press ENTER.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

2. Key in a new value in the Numeric Entry window (see Figure 3-6, page 3-4), using the
numeric keypad or the Up () and Down () cursor keys, then press ENTER.
3. Press RESET to save your change and return the WPC Initialization Menu.
To initialize press parameters, perform the procedure shown in the Initializing WPC 2000
Parameters section, page 4-34.

Setting the Top-stop Angle

NOTICE
For a variable-speed press, you need to determine the latest Top-stop Angle, which is the angle at
which the press top-stops at its slowest speed and with the shortest stopping angle/time.

NOTICE
BEFORE YOU SET THE TOP-STOP ANGLE, MAKE SURE THAT
• The press ram has been mechanically set to top dead center (TDC) (see NOTICE on page 2-3)
• The resolver has been aligned as close as possible to TDC (i.e., 0° ±2°) (see Mounting the
Resolver, page 2-25)
• The resolver has been zeroed (see page 2-78)

The value you enter in this field is the Top-stop “On” angle you determined in the Setting the
Top-stop “On” Angle procedure in Chapter 2 (see step 18, page 2-82).

Setting the Auto Carry-up Angle

! DANGER
INCORRECT AUTO CARRY-UP ANGLE
• Ensure that the Auto Carry-up Angle is correct. If the operator can reach the pinch point, the
Auto Carry-up Angle must be set so that any hazardous openings are smaller than 1/4 in. by the
time the crankshaft reaches the Auto Carry-up Angle.
• Determine the Auto Carry-up Angle for each tool, based on the crank angle at which the tool’s
hazardous openings are smaller than 1/4 in.
• Change the Auto Carry-up Angle to the correct value when you change tools.
Failure to comply with these instructions will result in death or serious injury.

NOTICE
The following Auto Carry-up function also applies to Foot Control. For more information about
using Foot Control for Single Stroke mode, see Single-stroke, Foot Operation, page 6-47 and
Enabling Foot Control in a Foot Switch, page 4-37.

WPC 2000’s Auto Carry-up feature (also called Operator Station Mute) enables the press to
complete a stroke whenever the operator releases the Run/Inch palm buttons after the ram has
passed the Auto Carry-up Angle.

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The Auto Carry-up Angle is factory-set to 149° if your WPC 2000 has light curtain firmware
and to 170° if you have non-light curtain firmware. If you change the auto carry-up default
setting, you must use an angle value that is at or past the crankshaft angle at which the pinch
point openings on the press have closed to less than 1/4 in. (6 mm). Pinch points that are less
than 1/4 in. (6 mm) are considered non-hazardous to the operator.
With large presses where the stroke is long and press speed is slow, you must ensure that the
operator cannot release the buttons and reach the pinch point before it closes. This applies
only when Two-hand Control is used to safeguard the point of operation (without light
curtain) and only if any opening allowing access to the pinch point is 1/4 in. (6 mm) or larger.
Set the Auto Carry-up Angle at the correct value to protect the operator.

Setting Micro-inch Time and Angle

Micro-inch Time is the length of time in milliseconds that the Dual Safety Valve is open when
the operator presses the Run/Inch buttons on the Operator Station while the press is in Inch
mode.
Normally, when the press is running in Inch (see Top-stop in Inch, page 6-41), the DSV is
open and the clutch engaged as long as the Run/Inch palm buttons are depressed. When
Micro-inch is enabled, the clutch remains engaged only for the length of time specified in the
MICRO TIME setting on the Press Control Parameter Menu unless the operator releases the
Run/Inch palm buttons before the period has expired.
You enable Micro-inch via the MICRO ANGLE setting on the Press Parameter Control
Menu. The Micro Angle default setting is 185°, which disables Micro-inch. To enable this
feature, change the Micro Angle to another setting between 186° and 184°. The angle you
specify enables Micro-inch for the range of angles between that value and 185°.
EXAMPLE
If you set the Micro-inch Angle to 186°, the press will automatically Micro-inch throughout the
stroke from 186° to 185°.
If you set the Micro-inch Angle to 300°, the press will Micro-inch from 300° to 185°. Normal
inching resumes from 185° to 300°.
You can enter Micro-inch values from 6 to 600 milliseconds. The default value, set at the
factory, is 100 mS.

Setting Clutch and Counterbalance Air Pressure Limits

The MAIN AIR LIMIT and CNTRBAL +/- items allow you to establish a low setpoint for
Clutch Air Pressure and a setpoint range for Counterbalance Air Pressure. Instructions for
installing sensors or switches to monitor Clutch and Counterbalance Air pressures are
provided starting on page 2-13.
The value you enter in the MAIN AIR LIMIT field sets the low limit for Clutch Air Pressure.
If clutch pressure drops below the limit, an F45 fault displays on the SmartPAC 2 LCD (see
page 7-14).

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

You can view the current Clutch Air Pressure and the Main Air Limit on the Press Control
Parameters screen in Run mode (see page 6-29). To disable clutch pressure monitoring, enter
zero (0) in this field. When you do so, clutch pressure readings and the Low Limit setting are
not displayed in Run mode.
The value you enter in the CNTR BAL +/- field sets the tolerance for the Counterbalance
Setpoint you establish in Program mode (see page 5-48). For example, if you program a
Counterbalance Setpoint of 40 psi and a Counterbalance Tolerance of +/- 5 psi,
Counterbalance Air pressures must remain within a range of 35 to 45 psi whenever the press is
at or passing through Top Dead Center (TDC). (Counterbalance pressure can vary outside
this range at Bottom Dead Center (BDC)). If the counterbalance pressure falls outside the
tolerance you set, an F46 fault displays on the SmartPAC 2 LCD (see page 7-14).
You can view the current Counterbalance Air Pressure and Counterbalance Setpoint on the
Press Control Parameters screen in Run mode (see page 6-29). To disable pressure
monitoring, enter zero (0) in this field. When you do so, the CNTR BAL SETPOINT field
will not display on the Press Control Parameters screen in Program mode, and counterbalance
pressure readings and the Counterbalance Setpoint will not display in Run mode.

Setting the Stop-time Limit

!DANGER
RECALCULATE SAFETY DISTANCE WHEN STOP TIME CHANGES
• Perform a 90° Stop Test any time you change the Stop-time Limit (see page 6-22).
• Recalculate the safety distance based on the new Stop-time Limit and adjust or reinstall
safeguarding devices according to the new safety distance.
Failure to comply with these instructions will result in death or serious injury.

This item enables you to set the limit for your press’s stopping time. The stopping time is the
time that it takes the crankshaft to stop once the dual safety valve (DSV) has been
de-energized. The Brake Monitor checks the stopping time of the press on every top-stop, and
whenever the stopping time increases to within 10 milliseconds of the Stop-time Limit you set
on this screen, the Brake Warning LED on the SmartPAC 2 front panel flashes. This warning
alerts maintenance personnel to perform the necessary repairs on the press.
Whenever the press’s stopping time exceeds the Stop-time Limit, SmartPAC 2 displays the
“STOP TIME EXCEEDED” message (see page 7-26) and prevents the press from operating
until the problem has been corrected.
The Stop-time Limit default is 500 mS, which is set when WPC 2000 is initialized (see
Initializing WPC 2000 Parameters, page 4-34). The Stop-time Limit you specify is displayed
on the Stop Time Status screen in Run mode (see BRAKE MONITOR, page 6-20).

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Calculating the Stop-time Limit

The value you set as the Stop-time Limit on the Press Control Parameter Menu must factor in
the normal wear on your brake to prevent SmartPAC 2 from generating stop-time faults when
the stopping time increases only a little. The Stop-time Limit can be easily calculated based
on the actual stopping time of your press. To perform this calculation, do the following:
1. Press RESET repeatedly until the Main Program Menu displays.
2. Perform the Determining the Stopping Time of Your Press procedure in Run mode (see
page 6-21).

NOTICE
ADD 10% FOR OLD BRAKES, 20% FOR NEW BRAKES
The rule of thumb for calculating the Stop-time Limit is to add 20% of the stopping time to
your press’s stopping time if your brakes are new, 10% if your brakes are old. Since
stopping time increases as the brake wears, the calculated Stop-time Limit should be
roughly the same for both new and old brakes.

3. Multiply the stopping time value you determined in step 2 by 0.20 (i.e., 20%) for a new
brake or 0.10 (i.e., 10%) for an old brake, and add the result to the stopping-time value.
This is your Stop-time Limit.

NOTICE
The Stop-time Limit must be at least 10 mS greater than the stopping time. Otherwise,
normal operation of press will cause the Brake Warning LED to flash.

Example 1
Your recorded stopping time is 207 mS and your brake is old. Take 10% of 207 (i.e., 0.10 x 207
= 20.7, rounded to 21) and add the result to 207 (i.e., 21 + 207 = 228). Your calculated
Stop-time Limit is 228 mS.
Example 2
Your recorded stopping time is 175 mS and your brake is new. Take 20% of 175 (i.e., 0.20 x
175 = 35) and add the result to 175 (i.e., 35 + 175 = 210). Your calculated Stop-time Limit is
210 mS.

Setting the Start-time Limit

The starting time of your press is the time it takes for the crankshaft to start turning after the
DSV has been energized. More specifically, it is the interval between the closing (turning on)
of the output relays on the DSV/Lockout Relay board, which provides the signal for the Dual
Safety Valve (DSV) to energize, and the resolver signal, which indicates that the crankshaft
has begun to turn. The greater part of this interval is the time it takes for the clutch
mechanism to activate and engage.
Whenever the start time exceeds the Start-time Limit you set on the Press Control Parameter
Menu, SmartPAC 2 displays an F79 (Loss of Rotation) fault on the SmartPAC 2 LCD (see

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

page 7-20) and prevents the press from starting. The Start-time Limit setting enables WPC
2000 to monitor operation of the resolver and detect resolver drive failure.
The Start-time Limit default is 1998 mS, which is set when WPC 2000 is initialized (see
Initializing WPC 2000 Parameters, page 4-34). The setting is automatically changed to twice
the starting time measured by WPC 2000 on the first stroke after initialization.
Wintriss recommends that you use this automatic setting as your Start-time Limit. If you
decide to change the setting, you should enter a value at least 40% greater than the measured
start time of your press. You can view the most recent starting time on the Stop Time Status
screen in Run mode (see page 6-21).
Example
Your measured start time is 250 mS. Take 40% of 250 (i.e., 0.40 x 250 = 100) and add the result
to 250 (i.e., 100 + 250 = 350). Your calculated Start-time Limit is 350 mS.

Setting the Shutdown Time (Optional)

NOTICE
Auto-compensated Top Stop (ACTS) firmware is required in order for WPC 2000 to implement the
Shutdown Time setting.

NOTICE
Since WPC 2000 uses the lockout relay to shut off the press motor when the Shutdown Time has
expired, the lockout relay must be wired to the motor starter in order for the Shutdown Time setting
to function (see page 2-34).

The Shutdown Time setting is the length of time WPC 2000 waits after the DSV de-energizes
before shutting off the press motor. When the DSV is de-energized, the motor may still be on
even though the press is not actually running. WPC 2000 uses the Shutdown Time value to
turn off the press motor if the DSV is not re-energized after the specified length of time. An
F10 fault code (see page 7-7) is displayed on the SmartPAC 2 LCD when the press has been
stopped. You can set the Shutdown Time to any value between 0 and 100 minutes.

Setting Flywheel Timer (Optional Hardware Required)

NOTICE
A flywheel speed sensor must be installed in order for the Flywheel Timer to function. See
page 2-43.

The Flywheel Timer setting allows WPC 2000 to prevent the press motor from being reversed
or Bar mode from being activated whenever the flywheel is turning at a speed greater than the
specified number of seconds per revolution.
A flywheel speed sensor must be installed in order for WPC 2000 to implement the Flywheel
Timer setting. The flywheel sensor monitors the length of time it takes the flywheel to turn
one revolution. As the flywheel slows down, the time for one revolution increases. The

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Flywheel Timer should be set to the cycle time below which it is safe to reverse or bar the
press. This setting affects both Forward-to-Reverse and Reverse-to-Forward changes in press
motor operation.
EXAMPLE
When the press is running at 60 strokes per minute (SPM), the length of time for one revolution
is 1 second (i.e., 60/60 = 1). As the press slows down to 3 SPM, the time increases to 20
seconds per revolution (i.e., 60/3 = 20). If you set the Flywheel Timer to 20 seconds, WPC 2000
will not allow reversal of the motor or barring of the press until the flywheel has slowed down to
less than 3 SPM.

Setting the ACTS Angle (Optional)

Auto-compensated Top Stop (ACTS) is an optional WPC 2000 feature that automatically
adjusts the Top-stop “On” Angle to an earlier point in the stroke to compensate for increases
in press speed. You enable ACTS via switch 4 on the Press Control Option Switch Menu (see
page 4-37 for instructions and for additional details about the ACTS feature).
The ACTS Angle setting allows you to specify the angle at which you want the press to stop.
In most variable speed applications, the ACTS angle should be set to 0°, the default value.
However, in top knock-out applications, the angle might be set after 0°, while in some
high-speed applications, it might be set before 0°. SmartPAC 2 will only accept ACTS Angle
entries between 330° and 30°. If you have questions about where to set the ACTS Angle,
contact Wintriss Tech. Support.

Selecting Pressure Units

The Pressure Units setting allows you to select the units in which pressure is displayed on
Press Control screens in Initialization, Program, and Run modes. Three Pressure Unit options
are available: PSI (Pounds per Square Inch), Kp (Kilopascals), and BAR (Bars). To select a
Pressure Unit, do the following:
1. With the highlight bar on the current PRESSURE UNIT setting, press ENTER until the
option you want is displayed.
Note that the units in which the MAIN AIR LIMIT and CNTRBAL +/- settings are
displayed change to the units you selected.

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Initializing WPC 2000 Parameters

NOTICE
INITIALIZE WPC 2000 PARAMETERS BEFORE PROGRAMMING SMARTPAC 2/WPC 2000
When you set up a new SmartPAC 2 with WPC 2000, initialize WPC 2000 press parameters
before you start programming your unit. See page 2-75.

NOTICE
RECORD WPC 2000 SETTINGS BEFORE INITIALIZING PARAMETERS
Use the Press Parameters Setup Sheet at the end of the manual to record your WPC 2000
settings before installing new firmware or initializing parameters.

NOTICE
Initializing press parameters resets WPC 2000 to its default settings. Initialize WPC 2000
parameters only when you set up a new SmartPAC 2 with WPC 2000 or install new WPC 2000
firmware.

When you first set up your SmartPAC 2 with WPC 2000 or when you install new WPC 2000
firmware, initialize WPC 2000 parameters by following the steps below. If you install new
WPC 2000 firmware in an existing system, first record press parameters so you can re-enter
them after initializing the system.
1. On the Press Control Parameter Menu, move the highlight bar to the INITIALIZE
PARAMETERS item, and press ENTER. The message shown in Figure 4-22 displays.

Figure 4-22. Initialize Parameters Warning Message

2. Press ENTER to continue the Initialize Parameters process

or
Press RESET to cancel the Initialize Parameters process.
The warning message disappears, and you are returned to the Press Control Parameter
Menu.

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Press Options
(INITIALIZATION – PRESS CONTROL – PRESS OPTIONS)
The Press Options item on the WPC Initialization Menu gives you access to the Press Control
Option Switch Menu, on which you can set the positions of eight switches on switch block
S101 on the WPC 2000 Main Processor board and make three operator mode settings. You
can set two additional switches on S102, but this must be done on the Main Processor board
itself.

Figure 4-23. Press Control Option Switch Menu

Setting Option Switches on S101

NOTICE
CYCLE POWER AFTER CHANGING OPTION SWITCH SETTINGS
Whenever you change an option switch setting, you must power down the WPC 2000 and power it
back up again in order to enable the new setting. If you do not cycle power, the previous switch
setting will remain in effect.

The SW1 through SW8 items control the position of switches on switch block S101 on the
WPC 2000 Main Processor board. Switches can be set to OPEN or CLOSED. To set one of
these items, do the following:
1. On the Press Control Option Switch Menu, move the highlight bar to the setting for the
switch you want.
2. Press ENTER until the setting you want is displayed.
3. Repeat steps 1 and 2 for each switch you want to set.
4. Press RESET when you are finished to save your settings and return to the WPC
Initialization Menu.
Settings for each switch are documented in the following sections.

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Switches 1 and 2 – Top-stop Angle Range

Options switches 1 and 2 control the range of angles within which the Top-stop “On” Angle
falls (see Installing the Overrun Sensor Magnet, page 2-82). WPC 2000 uses these switch
settings to determine at what angle to begin the overrun sensor closure test, which is used to
make sure that the overrun limit switch closes at the same angle on every stroke. Settings for
option switches 1 and 2 are shown in Table 4-5.

Table 4-5. Switches 1 and 2 Settings (S101): Top-stop “On” Angle Range
Top-stop Angle Range < 240° 241° to 270° 271° to 300° > 301°
Switch 1 Setting CLOSED CLOSED OPEN OPEN
Switch 2 Setting CLOSED OPEN CLOSED OPEN

Switch 3 – One-hand Control and Foot Switch Settings

When you have optional One-hand/Two-hand/Foot firmware, option switch 3 provides
settings for a One-hand Control or Foot Switch. Switch 3 enables Light Curtain Break mode
in a One-hand Control when “ONE HAND” is highlighted on the Mode Select Menu (see
page 6-39). Switch 3 enables either Foot Trip or Foot Control in a Foot Switch when “FOOT”
is the selected mode.
ENABLING LIGHT CURTAIN BREAK MODE IN A ONE-HAND CONTROL
When “ONE HAND” is highlighted on the Mode Select Menu, switch 3 controls the
conditions under which a One-hand Control (see Installing a One-hand Control, page 2-39) is
active, as shown in Table 4-6.
When switch 3 is set to OPEN, the One-hand Control is continuously active, allowing you to
initiate a stroke any time you push the One-hand Control switch.
When switch 3 is set to CLOSED, the One-hand Control is active only during the window
within which the operator breaks the light curtain to feed a part and for eight seconds after his
hand has cleared the light curtain. This condition is called Light Curtain Break mode. If the
operator presses the switch after this window has expired, the press will not start. The light
curtain must be broken again before the next stroke can be initiated.

Table 4-6. Switch 3 Settings (S101): Enabling Light Curtain Break Mode
Setting One-hand Control Functionality
OPEN Normal operation (Default). One-hand Control is
always active. Stroke can be initiated at any time by
pressing switch.
CLOSED Light Curtain Break mode. One-hand Control is active
only during window between initial breaking of light
curtain and 8 seconds after light curtain is cleared.

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ENABLING FOOT CONTROL IN A FOOT SWITCH

When “FOOT” is highlighted on the Mode Select Menu, switch 3 controls how the Foot
Switch must be activated in order to initiate and complete a stroke, as shown in Table 4-7.
Switch 3 Foot Switch settings apply only to Single-stroke operation.
When switch 3 is set to OPEN, the Foot Switch is in Foot Trip mode, which requires only that
the operator depress the Foot Switch, without holding it down, to initiate and complete a
stroke.
When switch 3 is set to CLOSED, the Foot Switch is in Foot Control mode, which requires
that the operator depress and hold down the Foot Switch through the Auto Carry-up Angle in
order to complete a stroke. If the Foot Switch is released before the Auto Carry-up Angle,
WPC 2000 issues an Emergency-stop command to the press.

Table 4-7. Switch 3 Settings (S101): Enabling Foot Control

Setting Foot Switch Functionality
OPEN Normal operation–Foot Trip (Default). When operator
depresses Foot Switch, press makes a complete
stroke.
CLOSED Foot Control enabled. Operator must depress and
hold down Foot Switch until the press has passed the
Auto Carry-up Angle in order to complete a stroke.

Switch 4 – Enabling Auto Compensated Top Stop (ACTS)

When you have Auto Compensated Top Stop (ACTS) firmware, switch 4 controls enabling of
the ACTS feature (see Table 4-8). ACTS is a WPC 2000 option that adjusts the Top-stop
“On” Angle to an earlier point in the stroke to compensate for increases in press speed.
ACTS is designed specifically for variable-speed presses. As the speed of the press increases,
the stopping angle increases, pushing the point at which the press actually top-stops past 360°,
or TDC. ACTS senses when the press has not stopped at TDC and compensates for this
lengthening of the stopping angle by moving the Top-stop Angle back an equivalent number
of degrees. The Top-stop Angle cannot be adjusted backward beyond 211°, the factory
setting.
Adjustment of the Top-stop Angle always lags behind press speed changes because ACTS
requires several Top-stops to fine tune its settings.
When switch 4 is set to OPEN, ACTS is disabled and the press operates normally. When
switch 4 is set to CLOSED, the ACTS feature is enabled, allowing the Top-stop Angle to be
adjusted as press speed increases.

Table 4-8. Switch 4 Settings (S101): Enabling ACTS

Setting ACTS Functionality
OPEN Normal operation (Default). ACTS disabled.
CLOSED ACTS enabled. Top-stop Angle is retarded as speed
of the press increases.

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If you use the ACTS feature, it is critical that you set the Stop-time Limit on your Brake
Monitor correctly so that you have advance warning of the need for brake maintenance (see
Setting the Stop-time Limit, page 4-30). Since increases in stopping angle may be due to brake
wear rather than to speed changes, ACTS may increase the difficulty of detecting brake
problems unless back-up systems are in place.

Switch 5 – Prior Act Time for Automatic Stroke Modes

Switch 5 controls the Prior Act time for Automatic Single-stroke and Automatic Continuous
On-demand operating modes if one or both of these options have been installed on your press
(see Table 4-9). The Prior Act time is the interval within which the activating signal from the
feed device or robot must be received in order to initiate a stroke.
When switch 5 is set to OPEN, its default setting, the activating signal must be received
within a 30-second window for Automatic Single-stroke and a 1-minute window for
Automatic Continuous On-demand. When switch 5 is set to CLOSED, the window increases
to 5 minutes for Automatic Single-stroke and 10 minutes for Automatic Continuous
On-demand.
Wiring instructions for Automatic Single-stroke are provided on page 2-46, operating
procedures on page 6-48. For information on wiring and operating Automatic Continuous
On-demand, call Wintriss Tech. Support.

Table 4-9. Switch 5 Settings (S101): Prior Act Times for Automatic Modes
Prior Act Time Prior Act Time
Setting Automatic Single-stroke Automatic Continuous On-demand
OPEN 30 seconds (Default) 1 minute (Default)
CLOSED 5 minute 10 minutes

Switch 6 – Enabling Dual Light Curtains

Switch 6 controls whether WPC 2000 recognizes dual light curtains when two light curtains
are wired to the system, as shown in Table 4-10. Refer to page 2-22 for general light curtain
installation instructions.
When switch 6 is set to OPEN, its default position, dual light curtains are disabled, and WPC
2000 recognizes only a single light curtain. When switch 6 is set to CLOSED, dual light
curtains are enabled, and both light curtains, if two light curtains are wired, are recognized.

Table 4-10. Switch 6 Settings (S101): Enabling Dual Light Curtains

Setting Dual Light Curtains
OPEN Normal operation (Default). Dual light curtains disabled.
WPC 2000 recognizes only one light curtain.
CLOSED Dual light curtains enabled. WPC 2000 recognizes two
light curtains.

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Switch 7 – Not Used

Switch 8 – Top-stop Mode for F and H Errors and Auxiliary Output 1 Response to
Interrupted Stroke
Switch 8 has two different functions. It controls how quickly the press top-stops when an F or
an H fault occurs, and if Auxiliary Output 1 on the WPC 2000 Main Processor board has been
wired, it also specifies how that output responds to an Interrupted Stroke condition.

NOTICE
CHANGES TO SWITCH 8 SETTING AFFECT BOTH SWITCH FUNCTIONS
When you change the option switch 8 setting for either the Top-stop or Auxiliary Output 1 function,
the new setting will affect operation of the other function.

SELECTING TOP-STOP MODE FOR F AND H ERRORS

! DANGER
PRESS MAKES ANOTHER STROKE AFTER BEING TOP-STOPPED ON F OR H ERROR
Use extreme caution if you set Switch 8 to OFF, which allows the press to complete another stroke
if an error occurs after 210°.
Failure to comply with these instructions will result in death or serious injury.

One switch 8 function specifies whether the press takes an additional stroke before it top-stops
when an F or an H fault occurs after 210° (see Table 4-11).
When switch 8 is set to OPEN, its default setting, the press top-stops on the current stroke
when an F or H fault occurs before 210°, or takes an additional stroke before it top-stops if the
error occurs after 210°. When switch 8 is set to CLOSED, the press top-stops on the current
stroke if an F or H fault occurs at any angle.

Table 4-11. Switch 8 Settings (S101): Top-stop Mode for F and H Errors
Setting Top-stop Behavior for F and H Errors
OPEN Normal operation (Default). Press top-stops on
current stroke when F or H fault occurs before 210°,
on next stroke if error occurs after 210°.
CLOSED Press top-stops on current stroke at whatever angle
an F or H error occurs.

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AUXILIARY OUTPUT 1 RESPONSE TO INTERRUPTED STROKE

! DANGER
NON-SAFETY OUTPUTS USED FOR SAFETY FUNCTIONS
Use auxiliary outputs 1, 2, and 3 for non-safety functions only, such as convenience in automation.
They cannot protect personnel from a moving hazard.
Failure to comply with these instructions will result in death or serious injury.

If you have wired Auxiliary Output 1 (see page 2-35), switch 8 also controls how this output
responds to an Interrupted Stroke condition, as shown in Table 4-12.
When switch 8 is set to OPEN, its default setting, Aux. Output 1 turns “off” during an
Interrupted Stroke and whenever a fault occurs, an E-stop string opens, or a light curtain is
broken with the press running. When switch 8 is set to CLOSED, the Auxiliary Output stays
“on” during an Interrupted Stroke when no fault condition or E-stop occurs but turns “off”
whenever there is a fault, an open E-stop string, or a light curtain interruption.

Table 4-12. Switch 8 Settings (S101): Auxiliary Output 1 Response to Interrupted Stroke
Settings Auxiliary Output 1 State Change
OPEN Normal operation (Default). Aux. Output 1 turns “off” when one
of the following occurs:
an Interrupted Stroke* condition
a fault condition (error code displays)
an open E-stop string
a light curtain interruption while press is running
CLOSED Aux. Output 1 stays “on” during Interrupted Stroke if no fault
condition or E-stop occurs, turns “off” when one of the
following occurs:
a fault condition (error code displays)
an open E-stop string
a light curtain interruption while press is running
* An Interrupted Stroke does not occur in Inch mode if the operator holds the palm switches
throughout the stroke. An Interrupted Stroke occurs in Inch only when the operator releases his
hands from the palm switches before the stroke is completed.

Making Operator Mode Settings

The DUAL OPERATORS, AUTOMATIC MODE, and TWO HAND ONLY items allow you
to make settings that control operator interaction with the WPC 2000. To set one of these
items, do the following:
1. On the Press Control Option Switch Menu, move the highlight bar to the operator mode
item you want.
2. Press ENTER until the setting you want is displayed.
3. Repeat steps 1 and 2 for each operator mode you want to set.

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4. Press RESET when you are finished to save your settings and return to the WPC
Initialization Menu.
Settings for each operator mode are documented in the following sections.

Dual Operators
The item allows you to enable Dual Operator Stations when two or more Operator Stations are
wired to WPC 2000 (see page 2-21) and to specify how the active Operator Station(s) is
selected. There are three options:
• NOT USED (Default). The Dual Operator Station feature is disabled. WPC 2000
recognizes only one Operator Station.
• SCREEN MODE. The Dual Operator Station feature is enabled, and the Active Op.
Station is selected on the SmartPAC 2 Run mode display.
• REMOTE SWITCH. The Dual Operator Station feature is enabled, and the Active Op.
Station is selected via a remote three-position switch. If you use this setting, you must wire
a remote selector switch. You can order such a switch from Wintriss (part no. 4256601).

Automatic Mode
This item allows you to enable Automatic Single-stroke or Automatic Continuous On-demand
operating mode if you have installed one of these options. Refer to page 2-46 for wiring
instructions and pages 6-48 and 6-51 for operating procedures. There are two options:
• DISABLED (Default). Automatic modes are disabled.
• ENABLED. Automatic modes are enabled.

Two Hand Only

NOTICE
One-hand/Two-hand/Foot firmware must be installed in order for this setting to be functional. Do
not set this item if you are running standard firmware.

This item allows you to make One-hand and Foot operating modes unavailable if you are
running One-hand/Two-hand/Foot firmware. If you are running standard firmware, this
setting is not functional. There are two options:
• DISABLED (Default). Two-hand Only operating mode is disabled, allowing the user to
select Two-hand, One-hand, or Foot mode to run the press.
• ENABLED. Two-hand Only operating mode is enabled, making One-hand and Foot
modes unavailable.

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Setting Option Switches on S102

NOTICE
Switches 1, 3 through 5, 7, and 8 on switch block S102 are not used.

This section shows you how to make settings on option switches 2 and 6 on switch block S102
on the WPC 2000 Main Processor board (see Figure 2-14, page 2-28 for location). All eight
S102 switches are factory-set to the OFF position. Only switches 2 and 6 are active. To set a
switch to ON (see Figure 4-24), push up on the switch with a small screwdriver or your
fingernail.

ON
Switch ON setting
Switch OFF setting (Default)
1 2 3 4 5 6 7 8
S102
-
Figure 4-24. S102 Option Switch OFF and ON Settings

Switch 2 – Auxiliary E-Stop Relay Muting Function

The Auxiliary E-Stop Output Relay board is an optional “daughter” board that enables up to
three auxiliary devices (e.g., feeds, transfers, etc.) to be stopped, or prevented from starting,
when one of three conditions exist: activation of an E-stop button, penetration of a light
curtain, and an “open” state in a cross-checked input.
Option switch 2 allows the Auxiliary E-Stop Output Relay board to be muted when a light
curtain is penetrated during the muted portion of the stroke (see Table 4-13). The switch is
functional only when your WPC 2000 has optional Shadow muting firmware, which disables
the light curtain during the portion of the stroke after the Auto Carry-up Angle has been
reached (see Setting the Auto Carry-up Angle, page 4-28).

Table 4-13. Switch 2 Settings (S102): Enabling E-Stop Muting Function

Setting Auxiliary E-Stop Output Muting Function
OFF Normal Operation (Default). Disables the muting function.
When the light curtain is obstructed during any portion of the
stroke, a stop command is issued to auxiliary devices.
ON Enables the muting function, allowing objects to penetrate the
light curtain during the muted portion of the stroke without
triggering a stop command for auxiliary devices.

When switch 2 is set to OFF, its default setting, muting of the Auxiliary E-Stop Output Relay
board is disabled, and penetration of the light curtain at any point in the stroke causes a stop
command to be sent to auxiliary devices. When switch 2 is set to ON, the Auxiliary E-Stop
Output Relay board is muted during the portion of the stroke when the light curtain is muted.

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If the light curtain is interrupted during this muting window, a stop command is not sent to
auxiliary devices.
Switch 2 enables muting of the Auxiliary E-Stop Output Relay board only during a light
curtain interruption. With switch 2 set to ON, the board functions normally (i.e., issues a stop
command) when an E-stop button is activated or a cross-checked input is open.

Switch 6 – Selecting Concurrent Time for More Than Two Operator Stations

NOTICE
You should only change this switch from its default setting if you have installed more than two
Operator Stations on your WPC 2000. Contact Wintriss Tech. Support for further information.

Option switch 6 on S102 allows you to select a 5-second concurrent time for WPC 2000
configurations with more than two Operator Stations installed, as shown in Table 4-14.

NOTICE
Do not attempt to install more than two Operator Stations until you have contacted Wintriss Tech.
Support. All Operator Stations in a mutli-Op.-Station configuration except the Op. Station wired to
the “A” inputs must contain a Two-hand Control module. Do not order standard Wintriss “Multiple
Operator Stations.”

Concurrent time is the 5-second interval within which each pair of palm switches on all
connected Operator Stations must be activated in order to start the press. If the concurrent
time is exceeded, the press will not start.
When switch 6 is set to OFF, its default position, and two Operator Stations are connected to
WPC 2000, the palm switches on each Operator Station must be pressed within a 1/2-second
window (called the “palm” or “synchronous” time) and both pairs of palm switches must be
pressed within a 5-second concurrent time window in order to stroke the press.
When switch 6 is set to ON and more than two Operator Stations are connected to WPC 2000,
palm switches on all connected Operator Stations must be pressed within a 5-second
concurrent time window to start the press. All Op. Stations connected to the “B” inputs must
contain a Two-hand Control module to provide the required 1/2-second palm (or
synchronous) time.

Table 4-14. Switch 6 Settings (S102): Selecting Concurrent Time for Multiple Op. Stations
Setting Concurrent Time for Multiple Op. Stations
OFF Normal Operation (Default). Establishes a 1/2-second palm (or synchronous)
time and a 5-second concurrent time for two Operator Stations.
ON Establishes a concurrent time of 5 seconds when more than two Operator
Stations are connected to WPC 2000. Also keeps a 1/2-second palm (or
synchronous) time for the Op. Station connected to the “A” inputs. Each
Operator Station connected to the “B” inputs must contain a Two-hand
Control module to provide the required 1/2-second palm (or synchronous)
time.

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Input Status
(INITIALIZATION – PRESS CONTROL – PRESS OPTIONS)
The Input Status item on the WPC Initialization Menu gives you access to the Display WPC
Input Status screen (see Figure 4-25), from which you can view the status of WPC inputs,
including buttons, switches, E-stops, Top-stops, interlocks, and transducers.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 4-25. Display WPC Input Status Screen

Input status screens for these items, which are displayed when you press the appropriate
function key, are provided as an aid to installation and troubleshooting.

NOTICE
The LEDs on the WPC 2000 Main Processor board also show the status of these inputs. See
Figure 2-41, page 2-89 for a map of LED locations.

When you press F2 (Buttons/Switches), the WPC Buttons and Switches Input Status screen
displays (see Figure 4-26, page 4-45).

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Figure 4-26. WPC Buttons and Switches Input Status Screen

When you press F3 (Estops/Top Stops), the WPC Estop and Top Stop Input Status screen
displays (see Figure 4-27).

Figure 4-27. WPC Estop and Top Stop Input Status Screen

When you press F4 (Interlocks), the WPC Interlock Group 1 Input Status screen displays (see
Figure 4-28, page 4-46). Input Status screens for additional user inputs are available if you
have installed the Option 1 daughter board (see Appendix J).

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Figure 4-28. WPC Interlock Group 1 Input Status Screen

When you press F5 (Transducers), the WPC Transducer Input Status screen displays (see
Figure 4-29).

Figure 4-29. WPC Transducer Input Status Screen

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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 operating modes and settings. You set user access on the Security
Access Menu, which is shown in Figure 4-30.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 4-30. 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 set to RUN.
• 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 4-15, page 4-48 for a complete list of security access settings):
• CHANGE COUNT 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 COUNT) 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, highlight the MUST BE USED selection.
Otherwise, select NOT REQUIRED.
• 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.

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Table 4-15. 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. PROPAC SENS PROGRAM AND RUN MODES
PROGRAM MODE ONLY
PASSWORD 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 PRESS CNTL 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 4-15. Security Access Settings (Cont.)

Optional modules included; your menu may be different

ADJUST RAMPAC PROGRAM AND RUN MODES

PROGRAM MODE ONLY
PASSWORD REQUIRED
ADJUST TOOL INFO 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 4-31) that asks you to enter your password.

ENTER YOUR PASSWORD

Give this number to

USE THE KEYPAD TO ENTER NUMBERS. Wintriss Tech. Support if
USE THE UP/DOWN CURSOR KEYS TO you forget your password.
INCREASE/DECREASE. PRESS ENTER
WHEN DONE. PRESS RESET TO CANCEL.
Note: Your number may be
different.
60599

Figure 4-31. “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.

Instructions for accessing menus in Program and Run modes are 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 4-50.

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.

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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 4-30, page 4-47). Note that the factory settings allow all actions
to be performed in both Program and Run modes for those items for which the
PROGRAM AND RUN MODES setting is available.
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 4-15, page 4-48 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 menus and settings unless one or
more of the following specific passwords is also required
• Init. Password–Provides access to the Main Initialization Menu
• PM Password–Provides access to the PM (Preventive Maintenance) Monitor option (see
Appendix C)
• 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.

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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 4-30, page 4-47), press F1 (Change Passwords)
to display the Set Passwords Menu (see Figure 4-32).

Figure 4-32. Set Passwords Menu

2. Select the password you want to change. The screen shown in Figure 4-33 displays.

Figure 4-33. “Enter a New Password” Screen

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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Additional Security
You can secure your WPC 2000 adjustments by installing a user-supplied keylock switch as
described in Wiring a Keylock Switch to Prevent Changes to WPC 2000 Settings, page 2-43.”
The switch works as follows:
• Switch ON (grounded): prevents changes to any WPC 2000 settings in Program and Run
modes
• Switch OFF (not grounded): Normal operation of Program and Run modes.
By using this keylock switch, you can prevent anyone from making changes to WPC 2000
settings in Program and Run modes. The keylock switch overrides the Security Access
settings discussed in the previous sections.
The following message displays at the bottom of the Press Control screen in Program and Run
modes when the keylock switch is closed at input 1:
THE PRESS CONTROL EDIT MODE IS LOCKED.

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

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“nnnnnnnn-Init.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 2-25,
page 2-51).
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 4-34).

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.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 4-34. Backup/Restore Control Menu

3. To begin the backup process, press the F6 (Backup) function key.

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)
where nnn is the amount of disk space in megabytes available for storing backup
information.

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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.

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 tool and Initialization
programming has been corrupted or if the SmartPAC 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 4-52) and the Backup/
Restore Control Menu (see Figure 4-34) 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 4-35, page 4-55.

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F1
F2
F3
F4
F5
F6
F7
F8

Figure 4-35. Backup/Restore Control Menu with Restore Confirmation Window Displayed

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 4-53). When the
restore is complete, the following message displays:
Finished Restore!
Press RESET to return to the Main Initialization Menu.

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 4-36. This screen is fully
documented starting on page H-7 for SmartPAC 2 users with the SFC firmware option. If you
have the LETS firmware option, refer to page I-7 for Set Communications Menu
documentation.

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Figure 4-36. Set Communications Menu

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 the 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 4-60.

The SETUP NETWORK item on the Main Initialization Menu allows you to set up
SmartPAC 2’s E-mail and SmartView functions and 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 4-37, page 4-57.

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Figure 4-37. 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
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:
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.

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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 network to view
the operation of each press in your pressroom from a remote location. (See Appendix E for
more information.) 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 the 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 4-38.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 4-38. Setup E-mail Screen

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To setup up E-mail, do the following:

1. Select SETUP E-MAIL on the Main Initialization Menu. The Setup E-Mail screen
displays.
2. With the highlight bar in the Mail Server: field, press ENTER. The Alphanumeric Entry
window, shown in Figure 4-39, displays with the default mail server shown at the top of
the window.

Figure 4-39. 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 4-16. You can also consult your
plant network administrator.

Table 4-16. Setup E-mail Items

Item Description Examples
Mail Server The name or IP address of the SMTP mail server.yourcompany.com
server on your network 124.15.62.53
Mail Port The port on the server used for mail. 25
Usually 25.
Use Secure Indicates whether a username and FALSE
Login password are required to log in to the
TRUE
network
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 username
to the network joe_user
Password The password (if necessary) for logging in password
to the network secret452
Email Error The e-mail address to which messages ErrorRecipient
Recipient issued when an e-mail fails to be delivered @yourcompany.com
are sent. SmartPAC 2 cannot receive joe.user@yourcompany.com
e-mail.

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Table 4-16. Setup E-mail Items (Cont.)

E-mail From Name to be shown in the “From” field in the FromRecipient
Name e-mail header. Some networks require a @yourcompany.com
particular format of “From” name. Press_14@yourcompany.com
Wintriss The e-mail address of Wintriss Tech. info@wintriss.com
E-mail Addr Support. Use the default unless instructed
otherwise.

4. Select the next item (e.g., Mail Port:, Use Secure Login:, etc.), and repeat steps 2 and 3,
referring to Table 4-16 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 4-68.

After you enter settings on the Network Utility Setup screen, you use SmartView to complete
setting up the e-mail messages and recipients for your SmartPAC 2 (see Appendix E).

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.

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 4-58) 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.

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DIAGNOSTICS
(INITIALIZATION – DIAGNOSTICS)
The DIAGNOSTICS item on the Main Initialization Menu gives you access to the
Diagnostics Menu (see Figure 4-40), 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 updated firmware to SmartPAC 2

Figure 4-40. 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 4-41, displays.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 4-41. Communications Data Viewer Screen

This screen allows you to verify communications between SmartPAC 2 and its installed
modules, including SFI and WPC. 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 4-42).

F1 F1
F2 F2
F3 F3
F4 F4
F5 F5
F6 F6
F7 F7
F8 F8

Figure 4-42. Transmit and Receive Data Screen: Combined View (Left), Split View (Right)

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. To toggle
between the two F1 key labels, press F1.

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In the “combined” view, Transmit and Receive data are shown together (see the left panel in
Figure 4-42), 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 4-42). 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 you want to
examine transmitted or received data, press F2 (Stop/Start Buffer). If no data or only partial
data is displayed, SmartPAC 2 and the other module are not communicating properly.
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 12 at the end of the manual. Figure 12 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 standard); 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 4-4, page 4-9).

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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 4-43, displays.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 4-43. 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 3-6,
page 3-4) 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 6-33), screen captures (see
page 3-23), 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 6-36).
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 3-24).
2. Access the Main Initialization Menu, select DIAGNOSTICS, and when the Diagnostics
Menu (see Figure 4-40) 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, refer to Appendix D.

Using SmartPAC 2 with a Link-motion Press

(INITIALIZATION – POSITION SENSOR)
If your SmartPAC 2 is installed on a link-motion press, you need to determine whether to use
NORMAL MOTION or LINK MOTION for your RESOLVER MOTION MODE setting (see
page 4-6) and, if you are using a servofeed with a Wintriss ServoFeed Interface (SFI), how
you will compensate for the different upstroke and downstroke speeds on your link-motion
press.

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To determine the proper RESOLVER MOTION MODE setting to use, run the press in
Continuous mode (if applicable) and observe the press speed in the lower right corner of the
Status box on the SmartPAC 2 display (see Figure 3-20, page 3-14).
• If press speed varies between the upstroke and downstroke, set RESOLVER MOTION
MODE to LINK MOTION (refer to Setting Link Motion, below)
• If press speed does not vary during the stroke, leave RESOLVER MOTION MODE set to
NORMAL MOTION and install and zero the resolver so that bottom dead center equals
180°. This setting will likely result in a top-dead-center reading of less than 360°, but this
value is acceptable in these circumstances. Refer to Chapter 2 for instructions on installing
(page 2-24) and zeroing (page 2-78) the resolver.

Setting Link Motion

(INITIALIZATION – POSITION SENSOR)
If press speed in Continuous mode varies during the stroke, set RESOLVER MOTION
MODE to LINK MOTION as follows:
1. Access the Main Initialization Menu, then select POSITION SENSOR.
2. Move the highlight bar to the RESOLVER MOTION MODE item, and press ENTER to
display the LINK MOTION setting.
3. Press RESET to return to the Main Initialization menu. Turn the Program/Run key to
RUN, and run the press to observe the behavior of the Press Speed value.

NOTICE
If WaveFormPAC is installed on your press and RESOLVER MOTION MODE is set to
LINK MOTION, WaveFormPAC comparison screens will not display the Ram Velocity.

Using a ServoFeed Interface with Link Motion

If you have a link-motion press and are using a servofeed with a Wintriss Servofeed Interface
(SFI), you can compensate for the change in speed between the upstroke and downstroke. In
a link-motion press, the upstroke is substantially faster than the downstroke, the downstroke
being slowed to improve forming operations. There are two methods you can use to
compensate for the variation in speed. Perform the following procedure to find out which
method to use, then refer to the appropriate section.
1. Access the Main Initialization Menu, and select FEED CONTROL.
2. On the Feed Control screen that displays, check to see if SETTLING TIME is one of the
parameters shown.
• If SETTLING TIME appears on the screen, go to Settling Time Compensation for Link
Motion (next)
• If SETTLING TIME does not appear, go to Setting the Shutdown Time (Optional) (see
page 4-67)

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Settling Time Compensation for Link Motion

If SETTLING TIME is a Feed Control Initialization parameter, follow the instructions below
to compensate for speed variation. Once you have set the Settling Time to the appropriate
value for one tool, you can use the Feed Advisor for all other tools on this press.
1. Access the Main Initialization Menu, and select FEED CONTROL.
2. On the Feed Control screen that displays, select SETTLING TIME and set it to 30 mS.
3. Switch to Program Mode (see Table 4-1, page 4-2), select the tool that is currently loaded,
then, on the Tool Program Menu, select FEED CONTROL (see Changing Settings for a
Loaded Tool, page 5-6.)
4. On the Servo-Feed Parameters screen, select FEED ADVISOR, then on the Servo-Feed
Advisor screen, select CALCULATE.
5. Press RESET to return to the Tool Program Menu, then press F5 (Load This Tool) to load
the tool. Cycle the press and notice whether feeding is complete at the correct time.
• If feeding is complete at the correct time, you are finished with settling time
compensation for link motion.
• If feeding is completed too late, access the Main Initialization Menu, select FEED
CONTROL, and increase the SETTLING TIME value by 3 mS. Then return to
Program mode, and use Feed Advisor to calculate a new value with this setting (see
steps 3 and 4). Load the tool number, and run the press to observe the feeding again.
Continue to increase the settling time by 3-mS increments until feeding is complete at
the correct time.
• If feeding is completed too soon, access the Main Initialization Menu, select FEED
CONTROL, and decrease the SETTLING TIME value by 3 mS. Then return to
Program mode, and use Feed Advisor to calculate a new value with this setting (see
steps 3 and 4). Load the tool number, and run the press to observe the feeding again.
Continue to decrease the settling time by 3-mS increments until feeding is complete at
the correct time.

Press Speed Compensation for Link Motion

NOTICE
Perform the press speed compensation procedure for each tool if Settling Time is not an
initialization parameter for this SFI.

If SETTLING TIME is not a Feed Control Initialization parameter, follow the instructions
below to compensate for speed variation. You must perform this procedure for every tool the
first time you program it.
1. Access Program mode (see Table 4-1, page 4-2), select the tool that is currently loaded,
then, on the Tool Program Menu, select FEED CONTROL (see Changing Settings for a
Loaded Tool, page 5-6.).

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2. On the Servo-Feed Parameters screen, select FEED ADVISOR, then on the Servo-Feed
Advisor screen, select PRESS SPEED, and enter a value 10% greater than the actual press
speed.
3. When you have changed the PRESS SPEED value, select CALCULATE.
4. Press RESET to return to the Tool Program Menu, then press F5 (Load This Tool) to load
the tool. Cycle the press and notice whether feeding is complete at the correct time.
• If feeding is complete at the correct time, you are finished with press speed
compensation for link motion.
• If feeding is completed too late, switch to Program Mode, increase Press Speed in the
Feed Advisor by 3%, and calculate a new value with this setting (see steps 2 and 3).
Load the tool number, and run the press to observe the feeding again. Continue to
increase Press Speed in the Feed Advisor by 3% increments until feeding is complete at
the correct time.
• If feeding is completed too soon, switch to Program Mode, decrease Press Speed in the
Feed Advisor by 3%, and calculate a new value with this setting (see steps 2 and 3).
Load the tool number, and run the press to observe the feeding again. Continue to
decrease Press Speed in the Feed Advisor by 3% increments until feeding is complete at
the correct time.

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 2-25, page 2-51).
• 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.
4. Select the name you want to enter (e.g., PRESS NAME), and when the Alphabetic Entry
window displays (see Figure 4-6, page 4-10), 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 panel to accept your entry.

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Chapter 5. SmartPAC 2 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
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, and make settings for
programmable cams, die protection sensors, press control parameters, 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 3-26, page 3-20 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
Press RESET.
until the Main Initialization Menu appears.
—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.
If the message “PRESS CONTROL IS IN LOCKOUT MODE” displays on the SmartPAC 2 front panel, turn
the Stroke Select key switch to OFF, then back to the desired operating mode to clear the message.

The first display you see in Program mode is the Main Program Menu (see Figure 5-1). From
this menu, you can access the Tool Manager screen (see next section) and the 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 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 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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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 4-6).
• 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 – 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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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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, 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 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, page 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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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 any 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 (F8) 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 4-47) 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 5 of the Copying an Existing Tool procedure, starting on page 5-4.

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:

Program Mode 5-5

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

1. On the Tool Manager screen, highlight the tool you want to load, and press F5 (Load
Tool). The 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 4-47).
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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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 4-47).
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, page 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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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 4-6.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 4-6), 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).

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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. 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 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, 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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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 crankshaft 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 4-47).
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 5-11

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

NOTICE
ARE YOU “LOCKED OUT”?
If you cannot change count values, security access for the CHANGE COUNT function may be set
to NO CHANGES ALLOWED. See SECURITY ACCESS, page 4-47.

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 has been 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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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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:

NOTICE
PULSE and TOGGLE settings are available only when ProCamPAC is an installed option. If you
attempt to make these settings when your system does not have a programmable cam, SmartPAC
2 will display a message indicating that the settings are not available.

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.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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.
7. Press RESET to return to the Counters screen.

Setting Counter Increment Angle

The crankshaft 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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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 pre-
load values in Run mode when the Batch preset is reached (see COUNTERS, page 6-8) as
long as you set the CHANGE COUNT parameter on the Security Access Menu in
Initialization to PROGRAM AND RUN MODES (see SECURITY ACCESS, page 4-47).
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.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

DIE PROTECTION (Optional)

(PROGRAM – GO TO THE TOOL MANAGER – select tool – F4-EDIT TOOL – DIE PROTECTION)

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

(DiPro 16-sensor option shown. Your display may look different.)

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 below.

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).

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 must 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 5-25.

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.
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 5-24.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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
crankshaft 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.

Green Sensors
A sensor input set to “green” must turn on during the Ready signal and turn off before the next
Ready signal (see Figure 5-17).

KEY OK OK not allowed not allowed

(press stops) (press stops)
TDC TDC TDC TDC

= Ready
Signal

= Sensor
ON
BDC BDC BDC BDC
Sensor ON only Sensor is ON Sensor never goes Sensor never goes
inside ready signal. inside ready signal OFF. ON.
and stays on for a
Green Sensor
time after the end of Stop signal sent at Stop signal sent at
ready signal, but beginning of ready end of ready signal.
turns OFF before signal.
next ready signal.

Figure 5-17. Ready Signal Programming for a “Green” Sensor

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 on 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

= Ready
Signal

= Sensor
ON

BDC BDC BDC BDC BDC

Green Sensor goes ON Sensor never goes Sensor is ON outside ready signal.
Quick Check only inside ready ON.
Sensor signal.
Stop signal sent at Stop signal sent when sensor is ON outside ready
end of ready signal. signal.

Figure 5-18. Ready Signal Programming for a “Green Quick Check” Sensor

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 OK not allowed not allowed not allowed

(press stops) (press stops) (press stops)
TDC TDC TDC TDC

= Ready
Signal

= Sensor
ON BDC BDC BDC BDC
Sensor staysON Sensor goes OFF Sensor never goes Sensor never goes
during entire ready before ready signal OFF outside ready ON.
Green ends.
Constant signal and goes OFF signal.
Sensor at least momentarily
outside the ready Stop signal sent Stop signal sent at Stop Signal sent at
signal. immediately. beginning of ready end of ready signal.
signal.

Figure 5-19. Ready Signal Programming for a “Green Constant” Sensor

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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.
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 5-23)
stroke counter
• Assign a name to each sensor (see page 5-22)
• Set the sensor type (i.e., red, yellow, green, etc.) (see page 5-24)
• Set stop type (i.e., Emergency Stop, Top Stop, and Smart Stop) (see page 5-25)
• Set the critical angle for a sensor programmed as Smart Stop (see page 5-26)
• Set the Ready signal for a green sensor (see page 5-28)
• Set the stroke count for a green special sensor (see page 5-29)

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

You are also shown how to change sensor settings (see page 5-30), view the sensor summary
(see page 5-31), and delete sensors (see page 5-31).

Setting the “Auto Enable by Tool” Counter Value

If you have set Sensor Enable Mode in Initialization to AUTO BY TOOL (see page 4-18),
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 6-6).
To set the Auto Enable by Tool counter, do the following:
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 4-47).
Figure 5-20. “Enter Your Password” Screen

F1
Number of strokes
after which DiProPAC F2
auto enables all sensors
in the tool F3
F4
F5
F6
F7
F8

Figure 5-21. Die Protection Sensor Menu with Auto Enable by Tool Counter

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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.

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 4-17).
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 seem suitable but you still want to name the sensor, select
“CUSTOM” NAME. The Custom Sensor Names screen, shown in Figure 5-23,
page 5-23, displays.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 4-18), 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 5-24).

Setting the “Auto Enable by Sensor” Counter Value

If Sensor Enable Mode is set to AUTO BY SENSOR in Initialization (see page 4-18), 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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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 6-6).
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. The name you selected for the sensor is 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 5-17 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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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 crankshaft rotation 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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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 5-29).
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 5-30).

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, page 5-27, displays.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Figure 5-27. Critical Angle Programming Screen

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 5-30).
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 5-30) 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.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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, displays.

Ready signal
On and Off angles

Highlighted arc
shows duration
of Ready signal

Figure 5-28. Ready Signal Programming Screen

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 5-16 for more information.

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 3-7.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

1. On the Ready Signal Programming screen, set the Ready On angle on the crank 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 crank 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 5-30) displays with all your sensor settings
shown.
4. If you want to change any settings, refer to Viewing and Changing Sensor Settings,
page 5-30).
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

After you select the stop type for a Green Special sensor, the Green Special Sensor Stroke
Count screen, shown in Figure 5-29, displays. On this screen, you set the number of strokes in
the interval between required Green Special sensor actuations.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 5-29. Green Special Sensor Stroke Count Screen

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

NOTICE
For more information about Green Special sensors, refer to Understanding Sensor Terminology,
page 5-16.

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) 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.

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 5-22) displays.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 through 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, 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.

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.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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). 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.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 5-32. Tool Program Menu with DIPROPAC 1-16 and DIPROPAC 17-32 Items

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.
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 5-20) 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, page 5-33) displays.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

F1
F2
F3
F4
F5
F6
F7
F8

Figure 5-33. Die Protection Sensor 17-32 Menu

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, page 5-34) displays.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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) displays.

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,
page 5-35) 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.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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),
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.

Figure 5-38. Sensor Settings Screen

7. Press RESET to return to the Die Protection Sensor 17-32 Menu.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 5-20) if necessary:
1. Perform steps 1 and 2 of the Programming Sensors 17-32 as Green, Green Quick Check,
or Green Constant procedure, page 5-32. 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) displays.

Figure 5-40. Sensor Type Screen with “GREEN SPECIAL” Highlighted

3. Select GREEN SPECIAL from the Sensor Type items.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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) 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.

Figure 5-42. Sensor Settings Screen

6. Press RESET to return to the Die Protection Sensor 17-32 Menu.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

CAM SWITCH (Optional)

(PROGRAM – GO TO THE TOOL MANAGER – select tool – F4-EDIT TOOL – CAM SWITCH)

! DANGER
PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE
Use SmartPAC 2’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 clutch/brake control or muting of light curtains.
Failure to comply with these instructions will result in death or serious injury.

NOTICE
MAXIMUM NUMBER OF TIMED AND AUTO ADVANCE CHANNELS PER TOOL
Each tool can have up to four Timed Output cam channels and up to two Auto Advance channels.

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, which appears on the Tool Program Menu only when ProCamPAC is installed,
enables you to program up to 8 (for 8-channel ProCamPAC) or 16 (for 16-channel
ProCamPAC) cam channels. Cam channel settings are made via the Cam Channel Menu,
which is shown in Figure 5-43.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 5-43. Cam Channel Menu

(ProCam 16-sensor 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 (Optional),
page 4-10).

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Channel numbers that are missing from the menu have been programmed as “global” cams in
Initialization (see SET GLOBAL CAMS (Optional), page 4-15). 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 channel. To do so, perform the following steps:

NOTICE
DO NOT USE CHANNEL 6, 7, OR 8 WHEN USING THE ASSOCIATED BATCH COUNTERS.
Cam channels 6, 7, and 8 are also used for batch counters 1, 2, and 3.

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 4-47).
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, displays.

Figure 5-45. Cam Channel Program Type Menu

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Instructions for programming cam channels, using each of the program types shown on
the Cam Channel Program Type Menu, are provided in the following sections.

Making an ON/OFF Setting

The PROGRAM ON/OFF ANGLES item on the Cam Channel Program Type Menu enables
you to program the crankshaft angles 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 5-41):
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.

F1
F2

Cam On and Off

F3
angles
F4
F5
Highlighted arc F6
shows “dwell”
of cam On signal F7
F8

Figure 5-46. Cam Channel On/Off Program Screen

2. Set the On angle on the crank angle clock, using the Left () and Right () cursor keys.
Refer to Using Cursor Keys to Set Timing, page 3-7 if you need help.
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.
3. Set the Off angle on the crank 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.
4. Press RESET when you are finished to return to the Cam Channel Program Type Menu.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Setting Multiple ON/OFF Cycles

SmartPAC 2 with ProCamPAC 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 16-channel ProCamPAC. Additional On/Offs you set for global cam channels (see SET
GLOBAL CAMS (Optional), page 4-15) 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 Unit: Examples

Total
Total
Ch Ch Ch Ch Ch Ch Ch Ch Extra
ON/
1 2 3 4 5 6 7 8 ON/
OFFs
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 5-40.
Figure 5-47 shows the Cam Channel On/Off Program screen set for an On angle of 228°
and an Off angle of 259°. Note the caption at the upper left of the screen indicating that
Arc 1 is selected.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 5-47. Cam Channel On/Off Program Screen: One On/Off Arc

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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 on the crank-angle clock, 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 299° and an Off angle of 318°.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 5-48. Cam Channel On/Off Program Screen: Two On/Off Arcs

4. Repeat steps 2 and 3 to add additional arcs. Figure 5-49, page 5-43 shows the Cam
Channel On/Off Program screen with a third arc programmed for an On angle of 14° and
an Off angle of 44°.
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.

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Selected (active) F1
arc shown here
and colored green F2
on crank angle
clock diagram F3
F4
F5
Inactive arcs
are grey
F6
F7
F8

Figure 5-49. Cam Channel On/Off Program Screen: Three On/Off Arcs

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 crankshaft angles 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 time that
the cam is On during the On-Off cycle 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.
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, page 5-44, displays.
2. Set the On angle on the crank angle clock, using the Left () and Right () cursor keys,
referring to Using Cursor Keys to Set Timing, page 3-7 if you need help.
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. In Figure 5-50 the On angle is set to 223°.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Figure 5-50. Cam Channel Timed Output Program Screen

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 350 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.

Making an Auto Advance Setting

NOTICE
You can program up to two Auto Advance output settings in Program mode. The first advance
constant set in Initialization mode controls the lowest-numbered Auto Advance channel in
Program mode. Likewise, the second advance constant controls the next numerically higher Auto
Advance channel. If channels 3 and 5, for example, are programmed as Auto Advance, channel 3
will use the first advance constant, channel 5 the second advance constant. See AUTO
ADVANCE and Slow RPM (Optional), page 4-12 for more information.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

The PROGRAM AUTO ADVANCE item on the Cam Channel Program Type Menu enables
you to program up to two cam channels as Auto Advance and to set On and Off angles for
those channels. Auto Advance cam settings automatically compensate for changes in press
speed, advancing cam timing as the speed of the press increases, delaying timing as speed
decreases. An Auto Advance cam channel is often used for Top Stop because it ensures that
the press will top-stop at the same angle regardless of varying press speeds. Auto Advance
settings are also used for feed, pilot release, lube, or other speed-sensitive application.
To program an Auto Advance cam channel, do the following:
1. Select PROGRAM AUTO ADVANCE on the Cam Channel Program Type Menu. The
Cam Channel Auto Advance Program screen, shown in Figure 5-51, displays.

Figure 5-51. Cam Channel Auto Advance Program Screen

2. Set the AutoOn angle on the crank angle clock, using the Left () and Right () cursor
keys, referring to Using Cursor Keys to Set Timing, page 3-7 if you need help.
As you press the Left () cursor key, the On cursor moves counterclockwise around the
display, and the AutoOn angle value decreases. When you press the Right () cursor key,
the On cursor moves clockwise around the display, and the AutoOn angle value increases.
The precise AutoOn angle value is displayed in the window inside the clock display. In
Figure 5-51, the AutoOn angle is set to 288°.
3. Set the Off angle on the crank 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 value increases. As you press the Down () cursor key, the Off cursor
moves counterclockwise around the display, and the Off angle value decreases.
The precise Off angle value is displayed in the window inside the clock display. In
Figure 5-51, the Off angle is set to 311°.
4. Press RESET when you are finished to return to the Cam Channel Program Type Menu.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Setting DSV ON Channel Timing

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 5-52.

Figure 5-52. 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. Instead of setting a specific time for
the Off delay, you can select the OUTPUT FOLLOWS RESOLVER MOTION setting, which
keeps the cam channel on until resolver rotation falls to 6 SPM.
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
or
Select the OUTPUT FOLLOWS RESOLVER MOTION setting by pressing the Down
() cursor key with “0” (zero) displayed in the OFF DELAY TIME field or the Up ()
cursor key with “254” displayed in the OFF DELAY TIME field.
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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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 5-53. 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 5-54, 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, below).

Figure 5-54. Cam Summary Screen

Viewing Global Cams

Global cams, which are programmed in Initialization mode (see SET GLOBAL CAMS
(Optional), page 4-15), are cam channels that can be used with any tool set up on your
SmartPAC 2. 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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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 5-55) displays with the name, program type, and
programmed settings shown for each channel set as a global cam.

Figure 5-55. Global Cam Summary Screen

PRESS CONTROL
(PROGRAM – GO TO THE TOOL MANAGER – select tool – F4-EDIT TOOL – PRESS CONTROL)

NOTICE
For help with the Press Control screen, press the HELP key when the screen is displayed.

This item on the Tool Program Menu enables you to program the following press control
parameters for each tool:
• Top-stop angle
• Maximum and minimum press speed limits
• Counterbalance setpoint
Settings are made on the Press Control Parameters screen, which is shown in Figure 5-56,
page 5-49.
The top-stop angle is the crankshaft angle at which the Top-stop command is given on your
press. This value is set by default to the Initialization Top Stop Default setting (see Setting the
Top-stop Angle, page 4-28). You can change the default setting for each tool to account for
differences in die weight, press speed, etc.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Figure 5-56. Press Control Parameters Screen

The maximum and minimum speed limit settings are provided to allow programming of tools
run on a variable-speed press. They apply to all Run operating modes–Continuous,
Single-stroke, and Inch. When the speed of the press exceeds the maximum limit, SmartPAC
2 stops the press and displays the fault message “Maximum press speed exceeded.” When
press speed drops below the minimum limit, SmartPAC 2 stops the press and displays the fault
message “Minimum press speed exceeded.” These fault message are documented in Chapter
7 (see page 7-30).
The counterbalance setpoint is used together with the counterbalance tolerance you set in
Initialization (see Setting Clutch and Counterbalance Air Pressure Limits, page 4-29) to
specify the pressure range outside of which an F46 (Counterbalance Air Outside Sensor
Limits) error displays on the SmartPAC 2 LCD. This field will not display if the Initialization
tolerance value is set to zero (0).
To make settings on this screen, do the following:
1. Select PRESS CONTROL on the Tool Program Menu. The Press Control Parameters
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 press speed
settings. Security access is set in Initialization mode (see SECURITY ACCESS,
page 4-47).
Figure 5-57. “Enter Your Password” Screen

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

NOTICE
If you have installed a keylock switch to prevent changes to WPC 2000 settings, the following
message is displayed at the bottom of the screen:
THE PRESS CONTROL EDIT MODE IS LOCKED
See Additional Security, page 4-52.

2. Select the item you want to program. The Numeric Entry window (see Figure 5-3,
page 5-3) displays.
3. Use the number keys to replace the default value with the setting you want, following the
directions in the window, and press ENTER. The window closes, and your entry appears
in the field you selected in step 2.
4. Repeat steps 2 and 3 for each item you want to program.

NOTICE
• The value you enter in the MAXIMUM PRESS SPEED field must be greater than the
Minimum Press Speed value. If the Maximum Speed setting is less than or equal to the
Minimum Speed value, SmartPAC 2 changes the Maximum Speed to one Stroke per
Minute greater than the Minimum Speed.
• To disable speed control, set both Maximum and Minimum Speed values to zero (0).

5. When you are finished, press RESET to return to the Tool Program Menu.

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 5-58, page 5-51.
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 4-19).

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

F1
F2
F3
F4
F5
F6
F7
F8

Figure 5-58. 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 4-47).
Figure 5-59. “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 (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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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

6. When you have finished entering tool information, 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 5-60.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 5-60. Sensor On/Off Status

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.

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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 6-6.

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.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

If you select a sensor with an “Off” status in Run mode, SmartPAC notifies you with the
following message:

Figure 5-61. “Sensor Turned Off” Message

5-54 Program Mode

Chapter 6. SmartPAC 2 Run Mode
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 (see Chapter 5 for
programming instructions) for individual tools and monitor press parameters such as speed
and sensor status. The chapter also shows you how to run the press. 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 currently loaded tool. 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 4-47 for instructions.
The following sections show you how to load a tool, adjust the tool’s counter, die protection,
cam, and speed limit settings, perform the 90° stop-time test, view tool information and the
error log, and toggle between the two sets of Hot keys. Instructions in how to run the press in
all its operating modes are also provided.
If you need help using the SmartPAC 2 keyboard to input information on Run mode displays,
refer to Chapter 3.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 3-28,
page 3-22 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 top-level menu, press RESET repeatedly until the Main menu appears.
If the message “PRESS CONTROL IS IN LOCKOUT MODE” displays on the SmartPAC 2 front panel, turn
the Stroke Select key switch to OFF, then back to the desired operating mode to clear the message.

NOTICE
For help with a Run mode screen, press the HELP key when that screen is displayed.

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.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 alternate
language 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).

PRESS #14
TOOL NUMBER 6160 PART CNTR 25346
CAMBIE
AL ESPANOL F1
FLANGE TWO HAND CONT
PRESS ANGLE 270 VIEW SENSOR
SUMMARY F2
VIEW GLOBAL
CAM SUMMARY F3
USE THE CURSOR KEYS ENABLE SENSORS
TO MAKE SELECTIONS. COUNTERS
PRESS ENTER TO
ACCESS SELECTION.
CAM SWITCH
BRAKE MONITOR
ADJ SENSOR
PART EJECTION F4
TONNAGE/WAVEFORM Use F1 - F8 as Hot keys
PROCESS MONITOR
FEED CONTROL
ADJUST CAM
SPRAY LUBE F5 If you have the Bilingual Option,
PM MONITOR F1 is reserved for changing
TOOL INFORMATION TONNAGE
F6 language and cannot be used
270
PLAN VIEW
SHUTHGT/CNTRBAL
ERROR LOG as a Hot key.
LOAD NEW TOOL
DIALOG MENU
DISPLAY
SHUT HEIGHT F7
TOGGLE HOT KEYS 1
ADJUST
SETPOINTS F8

Descriptive labels
for Hot keys

Figure 6-3. Main Run Menu, Showing Hot Keys Programmed

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 6-38). 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.”

Run Mode 6-3

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

NOTICE
If you add or remove a SmartPAC 2 option (e.g., DiProPAC, ProCamPAC, 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.

To program a Hot key, do the following:

1. 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.
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, page 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 4-47).
When you enter the password, you are given access to the item.

6-4 Run Mode

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 4-47).
Figure 6-5. “Enter Your Password” Screen

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. In most cases, 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. If sensor or cam adjustments have been locked out, the message “ADJUST
MODE LOCKED” appears on the Die Protection or Cam Switch menu. 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, with each fault listed in sequence beneath the
caption “ALL PENDING ERRORS.” To close the window, press RESET.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 6-6. Display All Errors Message Window

Run Mode 6-5

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Opening the Crankshaft Angle Window

You can open a window displaying the crankshaft angle at a magnification comparable to that
on the crank angle clock on the Main Run Menu for use on Run mode screens where a
prominent crankshaft 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 crankshaft 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. Crankshaft Angle Window Displayed on Main Run Menu

The crankshaft 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.

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 2-70 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, page 6-7, and this item is captioned DISABLE SENSORS. 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.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Figure 6-8. Main Run Menu with SENSORS ENABLED Display

To disable or enable sensors, do the following:

1. Press ENTER with the highlight bar on the DISABLE/ENABLE SENSORS item.
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

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, and the
message 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 page 4-18).
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 5-23 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. If you have enabled Setup Mode (see
page 4-19), you can 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.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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), 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 4-15, page 4-48.

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 4-15,
page 4-48). For instructions on entering counter and preset values, see page 5-9.

F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-10. Counters Screen

If you have set the CHANGE COUNT parameter on the Security Access Menu in
Initialization to PROGRAM AND RUN MODES (see page 4-48), 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 COUNT feature is enabled for Run mode, the label
RELOAD BATCH COUNTERS displays to the left of the F2 function key (see Figure 6-11,
page 6-9), and F2 becomes active. To reset batch counts to their pre-load values, simply press

6-8 Run Mode

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 7-23).

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)

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,
page 6-10), which displays when you select DIE PROTECTION. You can also view a
summary of information for all your sensors and a graphical display of sensor status from this
menu.

Run Mode 6-9

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

F1
F2
F3
F4
F5
F6
F7
F8

Figure 6-12. Die Protection Menu (Run Mode)

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).

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 4-15, page 4-48.

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. If you
select a sensor that has been turned off (see page 5-53), the following message displays.

Figure 6-13. “Sensor Turned Off” Message

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 5-16. Refer to Programming Sensor
Settings, page 5-20 for detailed instructions on programming sensors.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 6-14, displays.

Actual sensor
ON and OFF F1
angles
F2
F3
Adjust
Ready signal F4
on the fly
F5
F6
Sensor actuation
shown in green F7
F8

Figure 6-14. Ready Signal Programming Screen

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 crank angle clock. These displays allow you to fine-tune the Ready signal settings
made in Program mode.
Another difference is that the On and Off cursors move around the crank 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.

Run Mode 6-11

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 5-53). 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.

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 page 5-53), a message displays
indicating that the sensor is turned off (see Figure 6-13, page 6-10). 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 crank angle clock.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 5-29) except that it displays additional
information in the Status box.

NOTICE
If you have turned off the sensor (page 5-53), a message displays indicating that the
sensor is turned off (see Figure 6-13). Press ENTER to clear the message.

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.

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.

Run Mode 6-13

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Show 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 6-15, displays.

Black actuation block White actuation block

indicates sensor is indicates sensor is
grounded ungrounded

PRESS #14 CAMBIE

AL ESPANOL
TOOL NUMBER 6160 PART CNTR 51635
FLANGE TWO HAND CONT
PRESS SPEED 67

SENSOR STATUS

1 2 3 4 5 6 7 8

G G RED G GCONS G GQC G

9 10 11 12 13 14 15 16

GS 5 YEL GCONS N/U N/U N/U N/U N/U X indicates

sensor is
PRESS THE RESET KEY WHEN DONE. RETURN TO
turned off
MAIN MENU

Number indicates Color indicates Gray indicates not-used

maximum number type of sensor (unprogrammed) sensors
of strokes allowed (green, red, yellow)
for Green Special

Figure 6-15. Sensor Status Screen

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
• GCONS = 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.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 refresh 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.

Adjusting DiProPAC 32 Sensors

You access DiProPAC 32 sensors on the SmartPAC 2 Main Run Menu via the DIPROPAC
1-16 and DIPROPAC 17-32 items, as shown in Figure 6-16.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 6-16. Main Run Menu with DIPROPAC 1-16 and DIPROPAC 17-32 Items Shown

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 6-17, page 6-16, which shows the sensors that are used as examples in
Chapter 5).

Run Mode 6-15

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

F1
F2
F3
F4
F5
F6
F7
F8

Figure 6-17. 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.
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 6-18). 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.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 6-18. Ready Signal Programming Screen, Run Mode

6-16 Run Mode

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 at the bottom of the screen, indicating that you cannot change the green special stroke
count for this sensor (see Figure 6-19). 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 6-19. Green Special Sensor Stroke Count Screen, Run Mode

Run Mode 6-17

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

CAM SWITCH (Optional)

(RUN – CAM SWITCH)

! DANGER
PROGRAMMABLE CAM SWITCH NOT FOR SAFETY USE
Use SmartPAC 2’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 clutch/brake control or muting of light curtains.
Failure to comply with these instructions will result in death or serious injury.

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, which appears on the Main Run Menu only when ProCamPAC is installed, enables
you to adjust timing for each programmed cam channel. Adjustments are made via the Cam
Switch Menu (see Figure 6-20), which displays when you select CAM SWITCH.

F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-20. Cam Switch Menu

The Cam Switch Menu displays a list of the cam channels that have been set up in Program
mode. 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 (Optional), page 4-15).
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.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 4-15, page 4-48.

2. Adjust cam timings for the selected channel, following the instructions in the following
sections in Chapter 5:
• Making an ON/OFF Setting, page 5-40
• Setting Multiple ON/OFF Cycles, page 5-41
• Making a Timed Output Setting, page 5-43
• Making an Auto Advance 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 6-21.

Channel 3:
Auto Advance
timing (green)

Channel 4:
Timed output
(pink)

Channel 7:
ON/OFF timing
(dark blue)

Figure 6-21. Cam Timing Screen

Cam channels are displayed by number on the Y-axis. Only eight channels can be displayed
at a time, so if a 16-channel ProCamPAC is installed, you must press ENTER to display
channels 9 through 16. The X-axis displays the number of degrees of crankshaft rotation
(from 0° to 360°) at which channels turn on and off. The timing for each channel is shown as
a colored horizontal bar, the end points of which, when read against the crank angle “ruler” on
the X-axis, specify on and off settings for that channel. Bars are distinguished as follows:

Run Mode 6-19

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

• On/Off Channel: Dark blue bar whose end points are the channel’s On and Off settings
• Auto Advance Channel: Green bar with the letter “A” at each end. The bar’s end points are
the channel’s On and Off settings. As press speed increases, the bar will move to the left.
• Timed Channel: Pink bar with the letter “T” at the left end, indicating the On angle,
followed by a number (e.g., 350), which indicates the channel’s On time in milliseconds.
The Cam Timing screen is updated once every second.

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).

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).

BRAKE MONITOR
(RUN – BRAKE MONITOR)

!DANGER
RECALCULATE SAFETY DISTANCE WHEN STOP TIME CHANGES
• Perform a 90° Stop Test any time you change the Stop-time Limit (see page 6-22).
• Recalculate the safety distance based on the new Stop-time Limit and adjust or reinstall
safeguarding devices according to the new safety distance.
Failure to comply with these instructions will result in death or serious injury.

This item enables you to view your press’s starting and stopping times and stopping angle
and perform the 90° stop-time test to determine the longest stopping time of the press. You
can also view the Start-time and Stop-time Limits set in Initialization (see Press Parameters,
page 4-27). You view this information and perform this procedure on the Press Control Stop
Time Status screen, which is shown in Figure 6-22.

NOTICE
For help with the Stop Time Status screen, press the HELP key when the screen is displayed.

6-20 Run Mode

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Figure 6-22. Stop Time Status Screen

Stopping time is the time that it takes the crankshaft to stop once the dual safety valve (DSV)
has been de-energized. Starting time is the time it takes for the crankshaft to start turning after
the DSV has been energized. Instructions for setting Start-time and Stop-time Limits and
documentation of SmartPAC 2’s responses to start-time and stop-time faults are provided in
Press Parameters, page 4-27.
Stopping angle is the number of degrees that it takes the press to stop. It is equal to the ram’s
stopping position in degrees minus the crankshaft position when the DSV is de-energized.
(Stopping angle does not compensate for the complete rotation of the press when it takes more
than 360° to stop.) The stopping angle value helps you when you set up the top-stop cam. For
example, if the stopping angle is 100°, you would set the top-stop cam to turn on at 260°.

Determining the Stopping Time of Your Press

You need to determine the stopping time of your press at Top Stop in order to calculate the
Stop-time Limit to set in Initialization. To do so, perform the following steps:
1. Install the heaviest upper die you use on your press. Adjust the counterbalance for ram
weight, if your press has a counterbalance.

NOTICE
Before you can switch to Run mode, a tool must be programmed and loaded in Program
mode (see TOOL MANAGER, page 5-2).

2. Turn the Program/Run key to RUN to access Run mode, then select BRAKE MONITOR
on the Main Run Menu. The Press Control Stop Time Status screen displays.
3. Start the press in Continuous mode, and run the press until it reaches normal operating
speed.

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4. Top-stop the press and record the value (in milliseconds) displayed in the STOP TIME
VALUE (MSEC) field.
5. Repeat steps 3 and 4 five more times. Use the highest stop-time reading from your runs as
the value to use in calculating the Stop-time Limit (see Calculating the Stop-time Limit,
page 4-31).

Performing the 90° Stop-time Test

The 90° stop-time test is required by OSHA regulation 1910.217 and ANSI standard
B11.1-2009 to set the proper safety distance for personnel-guarding devices including light
curtains, two-hand controls, and type-B movable barriers. This test is performed at the press’s
most critical stopping point–90°. Follow these steps to perform the 90° stop-time test:
1. Install the heaviest upper die you use on your press. Adjust the counterbalance for ram
weight, if your press has a counterbalance.
2. With the Program/Run key set to RUN, select BRAKE MONITOR on the Main Run
Menu. The Stop Time Status screen displays.
3. Run the press in Continuous mode. If the press has a variable speed drive, set press speed
to the highest value you will normally use.
4. Press the Up () cursor key to start the 90° stop-time test. The following message
displays at the bottom of the screen:
90 DEGREE BRAKE TEST ARMED
PRESS RESET TO CANCEL TEST
5. When SmartPAC 2 emergency-stops the press, which occurs the next time the press
reaches 90°, record the STOP TIME value displayed on the Stop Time Status screen.
6. Repeat the test at least 5 more times.
7. Record the highest reading from all your tests. This is the value you should use in
calculating the safety distance.
8. Press RESET when you are finished to return to the Main Run Menu.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Calculating the Safety Distance

! DANGER
PRESS MAY NOT STOP BEFORE OPERATOR REACHES PINCH POINT
• Calculate the safety distance according to the applicable safety regulations, the instructions in
this chapter and in your light curtain user manual.
• Mount the Shadow light curtain heads at least the safety distance from the nearest pinch point
or hazardous area of your press (see Figure 6-23).
• Mount your Two-hand Control at least the safety distance from the nearest pinch point or
hazardous area of your press if you are using the Two-hand Control as a safety device.
• Mount your light curtain heads at least 7.5 in. (191 mm) from the nearest pinch point hazard,
even if that is greater than the safety distance you calculate.
Failure to comply with these instructions will result in death or serious injury.

Once you know your press’s stopping time, you can calculate the safety distance at which to
mount your Shadow light curtains (see the applicable Shadow user manual for more
information). The safety distance is the minimum distance from the pinch point (or hazardous
area) of the press at which light curtains can be installed and still be able to stop the press
before the operator can penetrate the light beam and reach the hazard (see Figure 6-23). The
“pinch point” is the area of the press where moving parts can cause injury.
If you have not installed light curtains and are using a Two-hand Control as a safety device,
you must mount the Two-hand Control at least the safety distance from the pinch point.

pinch point

Distance between
One of Shadow's light curtain and Shadow
invisible light beams pinch point receiver
Shadow transmitter

Figure 6-23. View of Light Curtains and Press Showing Safety Distance

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

ANSI and OSHA Safety Distance Formulas

! DANGER
PRESS MAY NOT STOP BEFORE OPERATOR REACHES PINCH POINT
• Calculate the safety distance carefully according to the instructions below.
• Mount your light curtain heads at least the safety distance from the hazardous area. If a light
curtain is too close to the hazard, there may not be enough time for the press to stop before the
operator’s hand (or another object) reaches the hazard.
• Mount your Two-hand Control, if you are using it as a safety device, at least the safety distance
from the hazardous area. If the Two-hand Control is too close to the hazard, there may not be
enough time for the press to stop before the operator’s hand (or another object) reaches the
hazard.
• Call Wintriss Tech. Support if you are not sure how to calculate the safety distance.
Failure to comply with these instructions will result in death or serious injury.

Occupational Safety and Health Administration (OSHA) regulations and American National
Standards Institute (ANSI) standards mandate that all machine safeguarding devices,
including Shadow light curtains, be located at the correct safety distance from the pinch point.
OSHA regulation 1910.217 governs the mounting of infrared light curtains to protect
mechanical power presses. Wintriss recommends, however, that you use the formula in ANSI
standard B11.1-2009 when calculating safety distance. The ANSI formula has been
developed specifically for guarding of mechanical power presses and includes more factors,
such as brake monitor setting, object sensitivity, and depth penetration factor, than the OSHA
formula. The B11.1-2009 formula represents a new consensus among manufacturers on the
proper installation of light curtains.
ANSI and OSHA formulas are documented in the following sections. For complete
information on OSHA regulation 1910.217 and ANSI standards B11.1-2009 and
B11.19-2003, see Appendix A.

The ANSI Safety Distance Formula

! DANGER
OBSERVE THE CORRECT SAFETY DISTANCE
• Calculate the safety distance carefully according to the instructions below, and mount your light
curtain heads at least the calculated distance from the hazardous area.
• Mount your light curtain heads at least 7.5 in. (191 mm) from the hazardous area, regardless of
the calculated safety distance.
• Be sure your value for Ts (i.e., stopping time) includes the response times of all devices that
react to stop the press. If your measurement for stopping time does not include the response
times of the press control, light curtain, and any other devices that react to stop the press, the
safety distance will be too short.
Failure to comply with these instructions will result in death or serious injury.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

! DANGER
USE BRAKE MONITOR TO CHECK STOPPING TIME
Use a brake monitor in light curtain applications to protect operators whose hands are routinely
exposed to a hazardous area, as required by OSHA 1910.217 (c) (3) (5). A brake monitor
continually checks that the machine’s stopping time does not exceed a predetermined limit.
Failure to comply with these instructions will result in death or serious injury.

The ANSI B11.1 safety distance formula, which is recommended by Wintriss, is

Ds = K x (Ts + Tc + Tr + Tbm) + Dpf
where
Ds is the ANSI safety distance in inches
K is the OSHA-recommended hand-speed constant of 63 inches-per-second
Ts is the stopping time of the press in seconds
Tc is the response time of the press control
Tr is the response time of the light curtain
Tbm is additional stopping time to compensate for brake wear
Dpf is the depth penetration factor
The hand-speed constant K indicates how far an individual could theoretically move his/her
hand and arm in one second.
Ts, Tc, and Tr are the worst-case response times of the press, of the control, and of the light
curtain. The response time of the press, Ts, is measured at approximately 90° of crankshaft
rotation or at maximum closing velocity. The response time of the control, Tc, is the time it
takes for the control to activate the machine’s brake. In the 90° stop-time test used by
SmartPAC 2 (see page 6-22), the calculated stop time includes both Ts and Tc values.
Response time, Tr, for Shadow light curtains is shown in Table 6-2.

Table 6-2. Shadow Light Curtain Response Time and Object Sensitivity
Shadow Model Head Length * Response Time Object Sensitivity
Shadow V 12 in. to 24 in. 30 mS
1.25 in.
36 in. and 48 in. 50 mS
Shadow VI 6 in. to 24 in. 30 mS
30 in. to 48 in. 35 mS 1.25 in.
60 in. 40 mS
Shadow VII 6 in. to 30 in. 20 mS
36 in. to 59 in. 23 mS
1.18 in.
Up to 96 in. 28 mS
Up to 135 in. 32 mS

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Table 6-2. Shadow Light Curtain Response Time and Object Sensitivity (Cont.)
Shadow Model Head Length * Response Time Object Sensitivity
Shadow 8 Up to 42 in. 23 mS
Up to 85 in. 32 mS
Up to 128 in. 41 mS 1.18 in.
Up to 171 in. 50 mS
Up to 202 in. 59 mS
Tbm is time added to the other response times in the ANSI formula to reflect brake wear. It is
calculated as follows:
Tbm = stop-time limit – stopping time at top stop
The Stop-time Limit is calculated in Initialization (see page 4-31). You can determine the
stopping time at top stop by performing the stop-time test procedure shown on page 6-21.
The depth penetration factor Dpf is a measure of how far an object, like an operator’s hand,
can move through the light curtain before the light curtain reacts. Dpf is related to the light
curtain’s object sensitivity, the smallest diameter object the light curtain can detect anywhere
in its field.
Object sensitivity (S) for Shadow 8 is 1.18 in. (30 mm) with beam centers of 0.79 in. (20 mm).
(See Table 6-2 for the object sensitivity of other Shadow models.) Based on S and ANSI
B11.1-2009, Dpf = 3.07 in. (78 mm).

NOTICE
ANSI SAFETY DISTANCE FORMULA FOR USE WITH TWO-HAND CONTROL
The formula for safety distance when using a Two-hand Control as a safeguarding device is similar
to the formula above, but does not include the response time of the light curtain nor the depth
penetration factor. The following is the ANSI formula for calculating the safety distance for use
with Two-hand controls:
Ds = K x (Ts + Tc + Tbm)
If you use a Two-hand Control as a safeguarding device, use this formula and perform the
calculation in a fashion similar to that described for the light curtain formula.

Example: Calculating the Safety Distance for a Light Curtain Using the ANSI Formula
The ANSI formula is
Ds = K x (Ts + Tc + Tr + Tbm) + Dpf
The following value is a constant:
K = 63 inches per second
We will use the following values for the variables in the formula:
Ts + Tc = 0.190 sec. (result of the 90° stop-time test)
Tr = 0.059 sec. (response time of Shadow 8 with 202 in. combined length including extensions)
Tbm = 0.035 sec. (see Example 2 in Calculating the Stop-time Limit, page 4-31)
Dpf = 3.07

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Putting these values into the formula, we get:

Ds = 63 x (0.190 + 0.059 + 0.035) + 3.07
Ds = (63 x 0.284) + 3.07
Ds = 17.89 + 3.07
Ds = 20.96 in., or, rounding, 21.0 in.
The light curtain must be mounted at least 21.0 in. away from the pinch point.
When using the ANSI formula, be sure to perform the calculations in this order:
(1) Add Ts + Tc + Tr + Tbm first.
(2) Multiply the result by 63.
(3) Add this result to Dpf. This is Ds.
If you do no follow this order, your safety distance calculation will be incorrect.

The OSHA Safety Distance Formula

! DANGER
OBSERVE THE CORRECT SAFETY DISTANCE
• Calculate the safety distance carefully according to the instructions below, and mount your light
curtain heads at least the calculated distance from the hazardous area.
• Mount your light curtain heads at least 7.5 in. (191 mm) from the hazardous area, regardless of
the calculated safety distance.
• Be sure your value for Ts (i.e., stopping time) includes the response times of all devices that
react to stop the press. If your measurement of stop time does not include the response times of
the press control, light curtain, and any other devices that react to stop the press, the safety
distance will be too short.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
USE BRAKE MONITOR TO CHECK STOPPING TIME
Use a brake monitor in light curtain applications to protect operators whose hands are routinely
exposed to a hazardous area, as required by OSHA 1910.217 (c) (3) (5). A brake monitor
continually checks to make sure that the machine’s stopping time does not exceed a
predetermined limit.
Failure to comply with these instructions will result in death or serious injury.

NOTICE
Wintriss recommends that you use the American National Standards Institute (ANSI) formula for
calculating safety distance because it contains more factors, allowing you to calculate the safety
distance more precisely. The ANSI formula is explained in the previous section (see page 6-24).

The OSHA safety distance formula as specified in OSHA regulation 1910.217 is

Ds = K x Ts

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

where
Ds is the OSHA safety distance in inches
K is the OSHA-recommended hand-speed constant of 63 inches-per-second
Ts is the stopping time of the press in seconds
The stopping time, Ts, must be measured at approximately 90° of crankshaft rotation or at
maximum closing velocity and include all components involved in stopping the press,
including the response time of the press control that activates the brake and the response time
of the light curtain (see Table 6-2, page 6-25).
The value calculated by SmartPAC 2 at the end of the 90° stop time test includes the stop time
of the press and response time of the press control (see page 6-22).
The Ts value should also include a percentage factor added for brake wear. A factor of 20
percent is recommended for presses with new brakes or brakes in good condition. A factor of
10 percent is recommended for presses with older brakes. See Calculating the Stop-time
Limit, page 4-31 for further details.

NOTICE
OSHA SAFETY DISTANCE FORMULA FOR USE WITH TWO-HAND CONTROL
The formula for safety distance when using a Two-hand Control as a safeguarding device is similar
to the formula above, but does not include the response time of the light curtain. Use the following
OSHA formula for calculating the safety distance for a Two-hand Control:
Ds = K x Ts
As indicated above, Ts must include all factors that are involved in stopping the press, including
the response time of the press control but excluding the response time of the light curtain.

Example: Calculating the Safety Distance for a Light Curtain Using the OSHA Formula
The OSHA formula is
Ds = K x Ts
The following value is a constant:
K = 63 inches per second
We will use the following values for the variables in the formula:
Stopping time of press + response time of press control = 0.190 sec. (result of the 90° stop-time
test)
Response time of light curtains = 0.059 sec. (Shadow 8 with 202 in. combined length including
extensions–see Table 6-2, page 6-25)
Additional time for brake wear = 0.035 sec. (see Example 2 in Calculating the Stop-time
Limit, page 4-31)
Putting these values into the formula, we get:
Ds = 63 x (0.190 + 0.059 + 0.035)
Ds = 63 x 0.284
Ds = 17.89 in., or, rounding, 17.9 in.
The light curtain must be mounted at least 17.9 in. away from the pinch point.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

When using the OSHA formula, be sure to do the calculations in this order:
(1) Add the factors involved in the stopping time Ts first.
(2) Multiply the result by 63. This is Ds.
If you do no follow this order, your safety distance calculation will be incorrect.

Adding to Safety Distance for Blanking Windows

When using fixed or floating blanking windows with your Shadow 8 light curtain, you must
add a factor to the calculated safety distance for each beam that is blanked. This applies
whether you use the ANSI or the OSHA formula. For a one-beam fixed blanking window,
you must add 5.38 in. (136.6 mm) to the calculated safety distance (ANSI formula). You
must add 5.76 in. (146.3 mm) to the calculated safety distance for a one-beam floating
blanking window (ANSI formula). See your Shadow 8 user manual for further details about
fixed and floating blanking.
If you are using another Shadow light curtain, refer the appropriate Shadow user manual for
the additional distance factor to add to the safety distance formula for each blanking window.

PRESS CONTROL
(RUN – PRESS CONTROL)

NOTICE
For help with the Press Control Parameters screen, press the HELP key when the screen is
displayed.

This item enables you to adjust the top-stop angle, maximum and minimum press speed
limits, and counterbalance setpoint established for the selected tool in Program mode (see
page 5-48). (The Counterbalance Setpoint field does not display if the Counterbalance
Tolerance has been set to zero (0) in Initialization mode.) You make these adjustments on the
Press Control Parameters screen, which is shown in Figure 6-24, page 6-30.
You can also view (but not adjust) the angles at which the overrun sensor turns on and off (see
Figure 6-25, page 6-31).
In addition, the current Counterbalance air pressure may be displayed if the Counterbalance
Tolerance is set to a value other than zero (0) in Initialization, and the Main Air pressure
setpoint and current Main Air pressure are shown if the Main Air Limit has been set to a
non-zero value in Initialization (see Figure 6-24).

Adjusting Program Settings

The top-stop angle is the crankshaft angle at which the Top-stop command is given on your
press. The top-stop angle default value is set in Initialization (see Setting the Top-stop Angle,
page 4-28) and adjusted in Program mode to account for differences in die weight, press
speed, etc. for each tool.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-24. Press Control Parameters Screen

The maximum and minimum speed limit settings are used to monitor press speed for tools run
on a variable-speed press. They apply to all Run operating modes–Continuous, Single-stroke,
and Inch. When the speed of the press exceeds the maximum limit, SmartPAC 2 stops the
press and displays the fault message “Maximum press speed exceeded.” When press speed
drops below the minimum limit, SmartPAC 2 stops the press and displays the fault message
“Minimum press speed exceeded.” These fault message are documented in Chapter 7 (see
page 7-30).
The counterbalance setpoint is used together with the counterbalance tolerance you set in
Initialization (see Setting Clutch and Counterbalance Air Pressure Limits, page 4-29) to
specify the pressure range outside of which an F46 (Counterbalance Air Outside Sensor
Limits) error displays on the SmartPAC 2 LCD. This field does not display if the
Initialization tolerance value is set to zero (0), disabling the Counterbalance Setpoint feature.
To adjust one or more of these settings, do the following:
1. Select PRESS CONTROL on the Main Run Menu. The Press Control Parameters 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 4-15, page 4-48.

2. Move the highlight bar to the desired item, and press ENTER. The Numeric Entry
window (see Figure 5-3, page 5-3) displays.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

NOTICE
• The value you enter in the MAXIMUM PRESS SPEED field must be greater than the
Minimum Press Speed value. If the Maximum Speed setting is less than or equal to the
Minimum Speed value, SmartPAC 2 changes the Maximum Speed to one Stroke per
Minute greater than the Minimum Speed.
• To disable speed control, set both Maximum and Minimum Speed values to zero (0).

3. Key in a new value, or use the Up or Down cursor key to increment or decrement the
existing value, and press ENTER. The window closes, and your change appears in the
field you selected in step 2.
4. Repeat steps 2 and 3 for each item you want to adjust.
5. When you are finished, press RESET to return to the Main Run Menu.

Displaying Overrun Sensor On/Off Angles

You can display the angles at which the overrun sensor turns on and off in order to verify that
you have installed the overrun sensor magnet correctly (see step 9 of the Installing the
Overrun Sensor Magnet procedure, page 2-82). To do so, perform the following steps:
1. On the Press Control Parameters screen, press F3 (Show Overrun Angles). A window like
the one shown in Figure 6-25 displays.

F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-25. Press Control Parameters Screen with Shown Overrun Angles Window

In addition to the Overrun Sensor On and Off angles, the window displays the angle at
which the Top-stop cam turns off. The value displayed in the Zeroed Top Stop Off field
allows you to verify that the Top-stop cam, which normally stays on for 20°, turns off
before the overrun sensor turns on.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

TOOL INFORMATION
(RUN – TOOL INFORMATION)

NOTICE
IF INFO IS CENTER 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

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 5-50). Adjustments are made on the Tool
Number Information screen, which is shown in Figure 6-26.

F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-26. 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.

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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 4-15, page 4-48.

2. Select a parameter you want to change. The Numeric Entry window (see Figure 5-3,
page 5-3) displays.
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 F5 for the first line, F6 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.

ERROR/EVENT LOG
(RUN – ERROR/EVENT 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 6-27, page 6-34),
that displays in reverse chronological order the 100 most recent errors or events that have
occurred at the press or within SmartPAC 2.
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 crankshaft 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 6-36).
Error messages displayed on the Error/Event Log are documented in Chapter 7.
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.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-27. Error/Event Log

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 4-47.

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 2 will display 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 6-28, page 6-35,
displays.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-28. 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 changes can be made.
See Table 4-15, page 4-48.

2. Highlight the tool you want and press F5 (Load Tool). The warning window shown in
Figure 6-29 displays.

Figure 6-29. 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.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 4-57), allows you to send e-mail messages to
recipients accessible via your SmartPAC 2 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 E).
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 6-30, which lists the recipients you have set up using SmartView.

F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-30. 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 6-31,
page 6-37.
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.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

F1
F2
F3
F4
F5
F6
F7
F8
Figure 6-31. Messaging Screen: List of Messages

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 6-32.

Figure 6-32. Sample E-mail to Wintriss Tech. Support

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1128600 SmartPAC 2 with WPC 2000 Integration 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.
When you select this item with the TOGGLE HOT KEYS 1 caption displayed, the second set
of Hot Keys is shown; when you select TOGGLE HOT KEYS 2, the first set of Hot Keys
appears (see Figure 6-33). 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 6-33. Toggle Hot Keys 1 and 2 Menu Items

Operating the Press

Responding to an Interrupted Stroke

! DANGER
INTERRUPTED STROKE DUE TO MACHINE MALFUNCTION
Investigate and correct the cause of the Interrupted Stroke before resuming operation of the press.
Failure to comply with these instructions will result in death or serious injury.

An Interrupted Stroke is a condition that occurs whenever the press is stopped before a stroke
can be completed, forcing the operator to return the press to its Top-stop position. The
command that stops the press may be issued by the operator or a safety device or be the result
of a fault condition.
When an Interrupted Stroke occurs, the message “Interrupted Stroke” flashes in the status box
at the top of the SmartPAC 2 screen (see Figure 3-2, page 3-2), and WPC 2000 automatically
switches to Two-hand Maintained Single-stroke mode. To clear the Interrupted Stroke, press
both Run/Inch palm buttons on the Operator Station until the press returns to top dead center.
When the press has returned to Top-stop, the “Interrupted Stroke” message is cleared, and
WPC 2000 switches back to the stroke and mode selected when the Emergency-stop occurred.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

When the Emergency-stop is caused by a system fault, you must first clear the error by
pressing the RESET key on the SmartPAC 2 front panel; then you can return the press to top
dead center.

Selecting Operating Mode

You select Inch, Single-stroke, or Continuous operation with the Stroke Select key switch on
the SmartPAC 2 front panel. To choose an operating mode for one of these stroke selections,
you must display the Mode Select Menu (see Figure 6-34), which you access by turning the
Stroke Select switch of OFF with SmartPAC 2 in Run mode.

F1
F2
F3
F4
F5
F6
F7
F8

Figure 6-34. Mode Select Menu

The Mode Select Menu may display up to five operating mode selections, depending on the
firmware and hardware options you have installed:
• Two-hand
• One-hand (Requires Two-hand/One-hand/Foot firmware and a Shadow light curtain)
• Foot (Requires Two-hand/One-hand/Foot firmware and a Shadow light curtain)
• Micro-inch Enabled (Must also be enabled in SmartPAC 2 Initialization–see page 4-29)
• Automatic (Must be enabled in SmartPAC 2 Initialization–see page 4-41)
To select an operating mode on the Mode Select Menu, do the following:
1. With the Program/Run key switch on the SmartPAC 2 front panel set to RUN, turn the
Stroke Select key switch to OFF to display the Mode Select Menu.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

2. Select the desired operating mode by pressing the appropriate function key:
• Press F4 to enable Micro-inch
• Press F5 to select One-hand mode
• Press F6 to select Two-hand mode
• Press F7 to select Foot mode
• Press F8 to select Automatic mode
3. Turn the Stroke Select switch the desired setting (i.e., Inch, Single-stroke, or Continuous).

Operating the Press in Inch Mode

! DANGER
IMPROPER SAFEGUARDING
Ensure that the machine guarding system is installed and maintained according to OSHA
regulation 1910.217, ANSI standards B11.1 and B11.19, and any other regulations or standards
that apply. Ensure that guarding is properly installed to prevent access to the machine over, under
or around any guarding device.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
INCH MODE NOT SUITABLE FOR PRODUCTION
DO NOT use INCH mode as a production mode, per ANSI B11.1-2009.
Failure to comply with these instructions will result in death or serious injury.

To operate the press in Inch mode, do the following:

1. Make sure the Program/Run key switch is set to RUN.
2. Turn the Stroke Select key switch of OFF.
3. Select one of the following options on the Mode Select Menu (see page 6-39):
• If a light curtain is installed on the press, select “TWO HAND” or “ONE HAND.” The
light curtain will be muted on the upstroke if WPC 2000 has the muting option.
• If no light curtain is installed, select “TWO HAND.” If you set the switch to
“ONE HAND,” WPC 2000 defaults to Two-hand mode.
4. Turn the Stroke Select key switch to INCH.
There are four different ways to operate the press in Inch mode:
• Top-stop in Inch
• Top-stop Bypass
• Micro-inch
• Dead Motor Inch

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Top-stop in Inch

NOTICE
Top-stop in Inch is enabled when there is no connection to pin #13 on the WPC 2000 Main
Processor board. This is the factory setting.

Top-stop in Inch is the default Inch mode. To run the press in Top-stop in Inch, do the
following:
1. To move the ram a short distance, press and hold both Run/Inch palm buttons on the
Operator Station at the same time, releasing them when the ram has reached the desired
point in the stroke.

NOTICE
If you are running the press in One-hand mode, you need to depress the left Run/Inch
button only.

The ram moves only as long as both Run/Inch buttons are depressed. Releasing one of the
buttons stops the ram immediately.

NOTICE
The ram will also stop if the light curtain is blocked during the non-muted portion of the
stroke, or if a system fault is detected.

2. Repeat the previous step to continue “inching” the ram.

3. To move the ram to Top-stop, press and hold both Run/Inch palm buttons until the ram
comes to a stop at the top of the stroke.
4. To initiate another stroke, release the Run/Inch buttons, then press and hold them until the
ram again comes to rest at the Top-stop position.

NOTICE
When “inching” the press, you may not notice when the ram top-stops.

Top-stop Bypass (Top-stop in Inch Disabled)

NOTICE
To disable Top-stop in Inch, connect pin #13 on the WPC 2000 Main Processor board to +24 Vdc.

Top-stop in Inch can be disabled so that the ram continues to cycle, without coming to a
Top-stop, as long as the Run/Inch buttons on the Operator Station are depressed. In this
alternative Inch mode, called Top-stop Bypass, the ram stops only when one or both buttons
are released.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Micro-inch

Micro-inch allows finer adjustments than are possible in Top-stop in Inch or Top-stop Bypass
and is designed to facilitate setup on high-speed or short-stroke presses. In Micro-inch, the
distance the ram moves is controlled by the time setting you make on the Press Control
Parameter Menu in Initialization mode (see Setting Micro-inch Time and Angle, page 4-29).
When that time has elapsed, the ram comes to a stop even though the Run/Inch palm buttons
are still depressed.
The ram can be stopped before the end of the Micro-inch time by releasing one or both Run/
Inch buttons. To move the ram through a complete stroke in Micro-inch, you must “inch” the
press to Top-stop. Micro-inch has no Top-stop feature.
Micro-inch is enabled via the MICRO ANGLE setting on the Press Control Parameter Menu
(see page 4-29) and function key F4 (Change Micro Inch Mode) on the Mode Select Menu
(see page 6-39).

Dead Motor Inch

Dead Motor Inch is a feature that allows you to operate the press in Inch mode for a short time
after the main motor is turned off, using the energy stored in the flywheel. Dead Motor Inch
allows the press to be inched in smaller increments than is possible when the press is running,
and is useful during setup. To activate Dead Motor Inch, do the following:
1. Turn off the press motor.
2. Turn the Stroke Select switch to “INCH.”
3. Press both Run/Inch buttons to initiate a stroke, releasing them when the ram has moved
the desired distance. Repeat this process until the flywheel has stopped turning.

Operating the Press in Single-stroke Mode

! DANGER
IMPROPER SAFEGUARDING
Ensure that the machine guarding system is installed and maintained according to OSHA
regulation 1910.217, ANSI standards B11.1 and B11.19, and any other regulations or standards
that apply. Ensure that guarding is properly installed to prevent access to the machine over, under
or around any guarding device.
Failure to comply with these instructions will result in death or serious injury.

To operate the press in Single-stroke mode, do the following:

1. Make sure the Program/Run key switch is set to RUN.
2. Turn the Stroke Select key switch of OFF.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

3. Select one of the following options on the Mode Select Menu (see page 6-39):
• Choose “TWO HAND” if you want to run the press in Two-hand mode
• Choose “ONE HAND” if you want to run the press in One-hand mode
• Choose “FOOT” if you want to run the press in Foot mode.

NOTICE
If you are running Two-hand Only firmware, One-hand and Foot modes are not available.

4. Turn the Stroke Select switch to “SINGLE STROKE.”

Instructions for operating the press in each Single-stroke mode are provided below.

Single-stroke, Two-hand Operation

! DANGER
OPERATOR STATION WIRED INCORRECTLY
Run all necessary tests to verify that each Operator Station is wired correctly and provides proper
anti-tie-down (see page 2-96) and anti-repeat (see page 2-97) protection.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
MORE OPERATORS THAN OPERATOR STATIONS
• Ensure that there are the same number of active operator stations as there are operators if the
press is not equipped with properly installed and operating light curtains.
• During setup, lockout/tagout the press if there are more operators than operator stations.
• Verify at every shift change that there are the same number of active operator stations as there
are operators if the press is not equipped with properly installed and operating light curtains.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
TWO-HAND CONTROL TOO CLOSE TO HAZARDOUS AREA
Verify at each shift change that any moveable Two-hand controls are located at least the safety
distance from the pinch point or hazardous area.
Failure to comply with these instructions will result in death or serious injury.

When performing the following procedure, make sure to press both Run/Inch buttons on each
installed Operator Station within the 1/2-second palm time (“synchronous” time in ANSI
terminology) and all pairs of Run/Inch buttons on all installed Operator Stations within the
5-second concurrent time. Also, confirm that the setting on S102 switch 6 is correct for your
Operator Station setup (see page 4-43).
To run the press, using Single-stroke, Two-hand operation, do the following:

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

1. With “TWO HAND” highlighted on the Mode Select Menu, initiate a stroke by pressing
both Run/Inch buttons, holding them until the ram reaches the Auto Carry-up Angle, then
releasing them (see Setting the Auto Carry-up Angle, page 4-28). The ram completes its
stroke automatically, stopping at Top-stop.

NOTICE
Both Run/Inch palm buttons on each Operator Station must be pressed within 1/2 second.
Each pair of Run/Inch buttons on all Operator Stations must be pressed within 5 seconds.
Make sure that the setting on S102 switch 6 is correct for your setup (see page 4-43).

If one or both Run/Inch buttons are released before the ram reaches the Auto Carry-up
Angle, the press stops. The press will also be stopped on the downstroke if a system fault
is detected or a light curtain is blocked.

Single-stroke, One-hand Operation

! DANGER
INCORRECT INSTALLATION
You must install a Shadow light curtain correctly and connect it to WPC 2000 properly in order to
run the press in Single-stroke, One-hand mode.
Failure to comply with these instructions will result in death or serious injury.

Single-stroke, One-hand operation can only be used with WPC 2000 systems running
Two-hand/One-hand/Foot firmware and employing a Shadow light curtain to guard the point
of operation. To run the press in this mode, do the following:
1. With “ONE HAND” highlighted on the Mode Select Menu, initiate a stroke by pressing
the left Run/Inch palm button, then releasing it. The ram completes its stroke
automatically, stopping at Top-stop.
The press is stopped if a system fault is detected or if a light curtain is blocked during the
downstroke.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Single-stroke, One-hand Control Operation

! DANGER
INSUFFICIENT SAFEGUARDS ALLOWING ACCESS TO HAZARD
• Follow all applicable OSHA and ANSI regulations for safeguarding your press system.
Point-of-operation safeguarding is the single most important factor in the prevention of injuries.
• Follow all applicable OSHA and ANSI regulations when installing a One-hand Control.
• Ensure that proper safeguarding devices are installed and working properly. Wintriss takes no
responsibility if safeguarding devices are not installed or working correctly.
• DO NOT use WPC 2000 or a One-hand Control as a safeguarding device.
• Install and operate WPC 2000 and a One-hand Control in accordance with OSHA and ANSI
regulations.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
PREVENT OPERATOR FROM STANDING BETWEEN LIGHT CURTAIN AND HAZARDOUS AREA
Ensure that the operator cannot position himself between the light curtain and the hazardous area.
Use another pair of light curtains or a mechanical barrier at knee to waist height to prevent the
operator or a passerby from being “trapped” between the light curtain and the hazard.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
INCORRECT INSTALLATION
You must install a Shadow light curtain correctly and connect it to WPC 2000 properly in order to
run the press in Single-stroke, One-hand Control mode.
Failure to comply with these instructions will result in death or serious injury.

NOTICE
When a One-hand Control is installed, you cannot use the Run/Inch palm buttons on the Operator
Station while the press is in One-hand mode. All other modes work normally as described in this
manual.

One-hand Control is a switch available from Wintriss that allows operators to use their free
hand to feed a part while their other hand operates the switch. This option can only be used
with WPC 2000 systems running Two-hand/One-hand/Foot firmware and employing a
Shadow light curtain to guard the point of operation.
One-hand Control can be used in two different modes. In Normal mode, the press cycles in
Single-stroke whenever you push the One-hand Control button. In “Light Curtain Break”
mode, the press cycles only when you push the One-hand Control button within 8 seconds of
removing your hand(s) from the light curtain. If the button is pushed after this interval
expires, the press does not cycle.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Light Curtain Break mode prevents inadvertent operation of the press when an operator is
loading or unloading parts.
You select the mode by setting option switch 3 on the Press Control Option Switch Menu (see
step 1, below).
To run the press in Single-stroke, One-hand Control mode, do the following:
1. Set option switch 3 on the Press Control Option Switch Menu to OPEN to operate the
press in Normal One-hand Control mode (see Enabling Light Curtain Break Mode in a
One-hand Control, page 4-36). Set switch 3 to CLOSED to operate in Light Curtain
Break mode.

NOTICE
If the “Interrupted Stroke” message flashes on the SmartPAC 2 display, press and hold the
Run/Inch palm buttons on the Operator Station to return the press to Top-stop. The
“Interrupted Stroke” message should disappear.

2. With “ONE HAND” highlighted on the Mode Select Menu, use the One-hand Control to
operate the press as follows:
• Press and release the One-hand Control button if option switch 3 is set for Normal
operation.
• Break the light curtain, then remove your hand and press the One-hand Control button
within 8 seconds if option switch 3 is set for Light Curtain Break mode.
The press will make a complete stroke, coming to rest at Top-stop.

NOTICE
The Prior Act lamp illuminates after the light curtain has been broken, and stays on for 8
seconds. If the One-hand Control button is not pushed within that time, the Prior Act lamp
will turn off. The press will not start until you break the light curtain again and push the
One-hand Control button within 8 seconds of removing your hand.

NOTICE
If the press does not run, turn off power to the press and WPC 2000. Recheck all wiring
connections. Try One-hand Control again. If the press still does not run, call Wintriss
Tech. Support.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Single-stroke, Foot Operation

! DANGER
INCORRECT INSTALLATION
You must install a Shadow light curtain correctly and connect it to WPC 2000 properly in order to
run the press in Single-stroke, Foot mode.
Failure to comply with these instructions will result in death or serious injury.

Single-stroke, Foot operation can only be used with WPC 2000 systems running Two-hand/
One-hand/Foot firmware and employing a Shadow light curtain to guard the point of
operation.
Two modes are available when you run the press in Single-stroke Foot. In Foot Trip mode,
you can initiate a complete stroke by simply pressing and releasing the Foot Switch. In Foot
Control mode, you must press and hold the Foot Switch through the Auto Carry-up Angle to
complete a stroke. You select the mode by setting option switch 3 on the Press Control
Option Switch Menu (see step 1, below).
To run the press in Single-stroke, Foot mode, do the following:
1. Set option switch 3 on the Press Control Option Switch Menu to OPEN to operate the
press in Foot Trip mode (see Enabling Foot Control in a Foot Switch, page 4-37). Set
switch 3 to CLOSED to operate in Foot Control mode.
2. With “FOOT” highlighted on the Mode Select Menu, depress the Foot Switch to initiate a
stroke, releasing or holding the pedal depending on the option switch 3 setting.
• Release the Foot Switch if option switch 3 is set for Foot Trip
• Hold the Foot Switch through the Auto Carry-up Angle if option switch 3 is set for Foot
Control
The ram completes the stroke, coming to rest at Top-stop.

NOTICE
INTERRUPTED STROKE
In Foot Control mode, if you remove your foot from the Foot Switch before the ram
reaches the Auto Carry-up Angle, the press will stop, the “Interrupted Stroke” message will
flash on the SmartPAC 2 display, and WPC 2000 will switch to Two-hand Maintained
Single-stroke mode for the remainder of the stroke. To clear the “Interrupted Stroke”
message and return to Single-stroke, Foot operation, press both Run/Inch palm buttons
on the Operator Station and hold them until the press returns to Top-stop.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Operating the Press in Automatic Single-stroke Mode

! DANGER
IMPROPER SAFEGUARDING
Ensure that the machine guarding system is installed and maintained according to OSHA
regulation 1910.217, ANSI standards B11.1 and B11.19, and any other regulations or standards
that apply. Ensure that guarding is properly installed to prevent access to the machine over, under
or around any guarding device.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
PRESS STARTING UNEXPECTEDLY
Ensure that light curtains and other safeguards are properly installed and operating to protect
operators when using Automatic Single-stroke. Since an external trigger initiates press operation,
a stroke can occur unexpectedly.
Failure to comply with these instructions will result in death or serious injury.

The Automatic Single-stroke function allows an external event to automatically initiate a

single stroke within a 30-second or 5-minute window, depending on the setting of option
switch 5 on the Press Control Option Switch Menu (see step 1, below). Generally, material
feed is used as the signaling event. However, other events such as part ejection or positive
part transfer can be used.
There are three requirements for Automatic Single-stroke:
• Automatic Single-stroke must be enabled in Initialization (see page 4-41)
• There must be a trigger mechanism.
• Proper guarding equipment, such as a Shadow light curtain and fixed guards, must be
installed to protect personnel.
As a triggering mechanism, you can use a single-pole, double-throw (SPDT) contact (switch
or relay) or two solid-state switches (NPN, open collector). See Figure 3 at the end of the
manual.
If you intend to use Automatic Single-stroke, contact Wintriss Tech. Support.
To run the press in Automatic Single-stroke, first install the sensors and other components
required for this function, then do the following:
1. Set option switch 5 on the Press Control Option Switch Menu to OPEN to select 30
seconds as the prior act timing or to CLOSED to select 5 minutes (see Switch 5 – Prior Act
Time for Automatic Stroke Modes, page 4-38).
2. Select “AUTOMATIC” on the Mode Select Menu (see page 6-39)
3. Set the Stroke Select key switch to “SINGLE STROKE.”

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

4. To initiate the first stroke, depress the Prior Act button–the Prior Act lamp will blink when
Prior Act is armed–then press and hold the Run/Inch palm buttons until the ram passes
bottom dead center.
The up stroke and all other strokes will be automatic.
It is not unusual for the press to pause at Top Stop. It is waiting for the “go” signal from
the external switch.
The external signal must occur after Top Stop within the time selected on switch 5 (30
seconds or 5 minutes). If WPC 2000 does not receive the signal within this period, it
assumes a problem has occurred and will not start the next stroke. If this happens, repeat
step 4.

Operating the Press in Continuous Mode

! DANGER
IMPROPER SAFEGUARDING
Ensure that the machine guarding system is installed and maintained according to OSHA
regulation 1910.217, ANSI standards B11.1 and B11.19, and any other regulations or standards
that apply. Ensure that guarding is properly installed to prevent access to the machine over, under
or around any guarding device.
Failure to comply with these instructions will result in death or serious injury.

To operate the press in Continuous mode, do the following:

1. Make sure the Program/Run key switch is set to RUN.
2. Turn the Stroke Select key switch of OFF.
3. Select “TWO HAND” on the Mode Select Menu if you want to run the press in Two-hand
mode; select “FOOT” if you want to run the press in Foot mode (see page 6-39).
4. Turn the Stroke Select switch to “CONT.”
Instructions for operating the press in each Continuous mode are provided below.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Continuous, Two-hand Operation

To run the press in Continuous, Two-hand mode, do the following:

NOTICE
You must press both Run/Inch palm buttons on the Operator Station within 8 seconds after you
press the Prior Act button in order to initiate Continuous mode operation. Otherwise, the press will
not start. The Prior Act lamp illuminates when you press the Prior Act button and turns off after 8
seconds.

1. With “TWO HAND” highlighted on the Mode Select Menu, press the Prior Act button on
the Operator Station, then, within 8 seconds, press both Run/Inch palm buttons and hold
them through the Auto Carry-up Angle. The ram will complete the stroke and continue
stroking until one of the following events occurs:
• You press the Top Stop button
• You press the Emergency Stop button
• A system fault is detected
• The light curtain is blocked during the non-muted portion of the stroke
The ram will stop in mid-stroke if you do not hold the Run/Inch palm buttons through the
Auto Carry-up Angle.

NOTICE
If the press is Emergency-stopped, WPC 2000 automatically changes to Two-hand
Maintained Single-stroke mode and the “Interrupted Stroke” message flashes on the
SmartPAC 2 display. To clear the “Interrupted Stroke” message, press and hold both Run/
Inch buttons to complete the stroke and return the ram to Top-stop.

Continuous, Foot Operation

! DANGER
INCORRECT INSTALLATION
You must install a Shadow light curtain correctly and connect it to WPC 2000 properly in order to
run the press in Continuous, Foot mode.
Failure to comply with these instructions will result in death or serious injury.

Continuous, Foot operation can only be used with WPC 2000 systems running Two-hand/
One-hand/Foot firmware and employing a Shadow light curtain to guard the point of
operation.
Option switch 3 settings, which govern Foot operation in Single-stroke (see page 6-47), do not
apply to Continuous, Foot operation.
To run the press in Continuous, Foot mode, do the following:

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

NOTICE
You must depress the Foot Switch within 8 seconds after you press the Prior Act button in order to
initiate Continuous mode operation. Otherwise, the press will not start. The Prior Act lamp
illuminates when you press the Prior Act button and turns off after 8 seconds.

1. With “FOOT” highlighted on the Mode Select Menu,” press the Prior Act button on the
Operator Station, then, within 8 seconds, depress and hold the Foot Switch pedal. The
ram will complete the stroke and continue stroking until you release the Foot Switch, at
which point the press will return to Top-stop.
As long as the Foot Switch is depressed, the press will continue to stroke but will stop if
one of the following events occurs:
• You press the Top Stop button
• You press the Emergency Stop button
• A system fault is detected
• The light curtain is blocked during the non-muted portion of the stroke

NOTICE
If the press is Emergency-stopped, WPC 2000 automatically changes to Two-hand
Maintained Single-stroke mode and the “Interrupted Stroke” message flashes on the
SmartPAC 2 display. To clear the “Interrupted Stroke” message, press and hold both Run/
Inch buttons on the Operator Station to complete the stroke and return the ram to Top
Stop.

Operating the Press in Automatic Continuous On-demand Mode

! DANGER
IMPROPER SAFEGUARDING
Ensure that the machine guarding system is installed and maintained according to OSHA standard
1910.217, ANSI B11.1, ANSI B11.19 and any other regulations and standards that apply. Ensure
that guarding is properly installed to prevent access to the machine over, under or around any
guarding device.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
PRESS STARTING UNEXPECTEDLY
• Ensure that light curtains and other safeguards are properly installed and operating to protect
operators when using Automatic Continuous On-demand mode, in which a stroke can occur
unexpectedly.
Failure to comply with these instructions will result in death or serious injury.

For information on using Automatic Continuous On-demand mode, call Wintriss Tech.
Support.

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Operating the Press in Bar Mode

! DANGER
INJURY WHEN USING BAR MODE
• Keep all personnel away from the press while it is being barred
• Use a spring-loaded turnover bar when you bar the press.
Failure to comply with these instructions will result in death or serious injury.

To operate the press in Bar mode, you must have the Bar Mode Control option. To activate
Bar mode and bar the press, do the following:
1. Make sure the Program/Run key switch is set to RUN.
2. Turn the Stroke Select key switch to OFF.
3. Select “TWO HAND” on the Mode Select Menu (see page 6-39).
4. Turn the Stroke Select switch to “INCH.”
5. Turn off the press motor.
6. On the Bar Control enclosure (see Figure 2-22, page 2-45), turn the Select switch to
“ON.”
7. When the flywheel stops turning, press the Operate button on the Bar Control enclosure.
8. Bar the press using a spring-loaded bar.

NOTICE
When barring the press, do not rotate the flywheel too quickly. If the crankshaft moves
faster than 6 SPM, WPC 2000 will stop the ram and fault code F26 will appear on the
SmartPAC 2 display. Press the RESET key to continue barring the press.

9. If an F26 error appears in the display, press the Reset/Select button to clear it, and
continue with the barring operation.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Multiple Operator Stations

! DANGER
HAZARDS EXPOSED BY NON-WORKING OPERATOR STATION
• Safeguard the point of operation exposed by the non-working Operator Station when using
multiple operator stations. The exposed area near a disabled Operator Station must be properly
guarded.
• Ensure that guarding is properly installed to prevent access to the machine over, under or
around any guarding device.
Failure to comply with these instructions will result in death or serious injury.

If you have wired two Operator Stations to your WPC 2000 (see Installing Multiple Operator
Stations, page 2-21) and option switch 6 on S102 is set to OFF (see page 4-43), the Run/Inch
palm switches on each Operator Station must be pressed within a 1/2-second “palm time”
(“synchronous time” in ANSI terminology), and both pairs of palm switches must be pressed
within a 5-second “concurrent time” window.

NOTICE
Do not attempt to install more than two Operator Stations until you have contacted Wintriss Tech.
Support. All Operator Stations in a mutli-Op.-Station configuration except the Op. Station wired to
the “A” inputs must contain a Two-hand Control module.

If you have installed more than two Operator Stations, you must set option switch 6 on S102
to ON to establish a 5-second concurrent time for all Op. Stations. In addition, all Operator
Stations except the Op. Station connected to the “A” inputs must contains a Two-hand Control
module to provide the required 1/2-second palm time (“synchronous” time in ANSI
terminology).
If you have dual Operator Stations, make sure to set the Operator Station Select Switch on the
front panel of your WPC 2000 to enable either the first station, the second station, or both
stations.

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6-54 Run Mode

Chapter 7. Fault Messages
! DANGER
PRESS MALFUNCTION
Correct or repair any fault before running the press again.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
IMPROPER REPAIR PROCEDURES
• Follow all procedures in this manual.
• Perform only the tests and repairs listed in this manual.
• Lockout/Tagout the press during all installation, modification, repair, or maintenance procedures.
• Use only factory-supplied replacement parts.
• Ensure that all safety procedures are followed during installation, operation, and repair of
SmartPAC 2 and WPC 2000.
• Ensure that SmartPAC 2 and WPC 2000 are installed, tested, and repaired by qualified
personnel.
• Perform the final checkout tests (see page 2-87) after every modification, repair, or change to
the press, press control or other equipment.
Failure to comply with these instructions will result in death or serious injury.

! DANGER
IMPROPER SAFETY SWITCHING RELAY REPAIR
Replace the DSV/Lockout Relay board or Auxiliary E-stop Relay board (see Figure 2-14,
page 2-28) before placing the WPC 2000 back into operation after the first occurrence of a fused
relay.
If a relay fuses
• DO NOT reset the WPC 2000 to restart the machine.
• Remove the WPC 2000 from operation immediately and replace the defective relay board
before operating the press again.
Failure to comply with these instructions will result in death or serious injury.

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 with WPC
2000 Integration); installed options (e.g. DiProPAC, ProCamPAC, etc.); and firmware version
number (e.g., Vs. 7.77). You can determine the last two items by accessing the Installed Options
screen in Initialization mode (see page 4-9).

Fault Messages 7-1

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

NOTICE
E-MAIL TROUBLESHOOTING INFORMATION TO WINTRISS TECH. SUPPORT
You can send an e-mail containing the error log and other information to Wintriss Tech. Support.
• If your SmartPAC 2 is networked, you can e-mail files directly from the control. See page 6-37.
• If your SmartPAC 2 is not networked, you can load the files onto a USB disk (see page 4-65),
take them to a networked computer, and e-mail them.

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
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.

7-2 Fault Messages

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Lockout Message
Certain press control faults, called Lockout faults, generate the message “PRESS CONTROL
IS IN LOCKOUT MODE” on the SmartPAC 2 display after the fault is cleared. These are
serious error conditions and require an additional step. When the problem has been corrected
and the fault cleared, perform the following steps to clear the Lockout condition, following
the instructions in the message.
1. Turn the Stroke Select switch to “OFF.”
2. Turn the Stroke Select switch to “INCH” or one of the other stroke selections.
The Lockout message is cleared.
Press control fault codes that generate the lockout message are identified by an asterisk (*) in
documentation of the faults (see Messages for Press Control Problems, page 7-5).

Brake Monitor Faults

Brake Warning LED
When the Stopping Time of the press increases to within 10 mS of the Stop-time Limit set in
SmartPAC 2 Initialization (see Setting the Stop-time Limit, page 4-30), the amber Brake
Warning LED will flash. Illumination of this LED often means that the brake is wearing and/
or defective. To respond to this error, do the following:
1. Contact your maintenance crew immediately and have them investigate the condition of
the brake.
2. If the brake checks out, your Stop-time Limit is too tight, not allowing for normal wear.
Set a new Stop-time Limit, following the instructions starting on page 4-30.
3. Power down the WPC 2000, then power the unit back up to turn off the Brake Warning
LED.

Stop Time Exceeded

! DANGER
INCORRECT SAFETY DISTANCE DUE TO INCORRECT STOP TIME
• Perform a 90° Stop Test any time you change the Stop-time Limit. See page 6-22 for
instructions.
• Recalculate the safety distance based on the new Stop-time Limit and adjust or reinstall
safeguarding devices according to the new safety distance. See Calculating the Safety
Distance, page 6-23.
Failure to comply with these instructions will result in death or serious injury.

Fault Messages 7-3

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

! DANGER
PRESS MALFUNCTION
Correct or repair any press malfunction or wiring error before restarting the press.
Failure to comply with these instructions will result in death or serious injury.

When the Stopping Time of the press exceeds the Stop-time Limit, the following message
displays on the SmartPAC 2 LCD
The Stopping Time of the press has
exceeded the Stop Time Limit. Check
the brakes and make sure that the
press is safe to operate.
and WPC 2000 prevents the press from being operated until the brake has been completely
repaired.

NOTICE
BRAKE WARNING
The Brake Warning LED alerts you when the Stopping Time of the press is within 10 mS of the
Stop-time Limit.

To respond to this fault, do the following:

NOTICE
If you try to run the press without first repairing the brake, WPC 2000 will stop the press on the
next stroke and again display the Stop Time Exceeded fault on the SmartPAC 2 display. The fault
will continue to appear until the brake has been repaired.

1. Contact your maintenance crew and have them repair the brake immediately.
2. When the brake has been repaired, press the RESET key to clear the Stopping Time fault.
3. When the Lockout message displays (see page 7-3), turn the Stroke Select switch to
“OFF,” then to “INCH” to clear the message.
4. Run the press several times to determine its Stopping Time, and compare this value to the
result of your last Stop-time tests, referring to the procedure starting on page 6-22.
5. Determine whether you need to adjust the previous Stop-time Limit, and make
adjustments if necessary.

7-4 Fault Messages

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Messages for Press Control Problems

! DANGER
PRESS MALFUNCTION
Correct or repair any press malfunction or wiring error before restarting the press.
Failure to comply with these instructions will result in death or serious injury.

Whenever WPC 2000 detects a problem with the clutch/brake control, the press, or peripheral
equipment, it sends a Stop command to the press and generates a fault on the SmartPAC 2
display. Most of these faults include a three-character alphanumeric code (see Figure 7-3 for
an example). The initial letter, E, F, or H, indicates how to clear the fault after it has been
corrected and, in the case of F and H faults, specifies the processor (WPC 2000 has two
processors) that reported the problem, as shown in Table 7-1.

Figure 7-3. WPC 2000 Display Showing Fault Code

Table 7-1. Fault Codes: Significance of Initial Letter

Initial Letter Significance
E To clear the fault, you must power down the WPC 2000, then
power the unit back up. The fault cannot be cleared by
pressing the RESET key.
F Generated by the main processor. To clear the fault, press the
RESET key.
H Generated by the second processor. To clear the fault, press
the RESET key.

Fault Messages 7-5

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

The two-digit number following the initial letter identifies the specific WPC 2000 fault. For
example, fault code F53, which is shown in Figure 7-3, indicates a problem with the
equipment connected to User Input 3, the name of which (i.e., “Die Nitrogen”) has been
programmed by the user in SmartPAC 2 Initialization (see User Interlocks, page 4-24). Each
of the 7 non-control-reliable user inputs and each pair of the 2 cross-checked control-reliable
inputs is provided with a unique status code. Fault codes also document problems with the
resolver, Dual Safety Valve (DSV), Operator Station, and other WPC 2000 components.
To respond to a fault, do the following:
1. Correct the problem that caused the fault.
2. Clear the fault code or message on the SmartPAC 2 display by doing one of the following:
• To clear F and H faults, press the RESET key on the display or a Remote Reset switch if
one is installed.
• To clear E faults, power down SmartPAC 2 and WPC 2000, then power the units back
up.
All E, F, and H faults are documented in numerical order in the following sections.

Resolver Faults

NOTICE
CLEARING “E” FAULT CODES
To clear E fault codes, do the following:
1. Power down SmartPAC 2 and WPC 2000.
2. Power up SmartPAC 2 and WPC 2000.

E06
Problem: The press is running faster than 1000 SPM, the resolver has failed, or the wiring in
the resolver circuit to WPC 2000 is loose or bad.

Remedy: If WPC 2000’s rated press speed is exceeded, reduce the speed. If press speed is
not the problem, check the resolver wiring for shorts, breaks, or loose connections
(see Wiring the Resolver, page 2-25). If wiring is not the problem, the resolver is
probably bad and will have to be replaced. If necessary, contact Wintriss Tech.
Support for assistance or replacement of the resolver.

7-6 Fault Messages

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

F04 or F05
Problem: Resolver wiring is faulty, or the resolver itself is bad.

Remedy: Check resolver wiring, making sure that the screws on the terminals are tightened
on bare wire and not on insulation (see Wiring the Resolver, page 2-25). Also
check the resolver. If necessary, contact Wintriss Tech. Support for assistance or
replacement of the resolver.

E07
Problem: During zeroing, the resolver has been set outside the range of 330° to 30°.

Remedy: Re-zero the resolver at top dead center (see Zeroing the Resolver, page 2-78).

Operational Faults

NOTICE
CLEARING LOCKOUT MESSAGE
To clear the Lockout message, do the following:
1. Turn the Stroke Select switch to “OFF”
2. Turn the Stroke Select switch to “INCH”.

F10*

NOTICE
This code is not displayed when Two-hand Inch operating mode is selected to enable Dead Motor
Inch.

Problem 1: If the message accompanying the fault code is “PRESS MOTOR IS OFF,” the
main motor has been turned off by the operator or as the result of Lockout (see
page 7-3). This message displays following Lockout only when you have wired
the lockout relay to the motor starter as instructed on page 2-34.

Remedy 1: Turn the motor back on to reset the fault, clearing the Lockout message first (see
NOTICE, below) if necessary. If the motor won’t turn on, you may need to
replace the Forward contact blocks on the starter with new ones. To access Run
menus without starting the motor, set the press to Two-hand Inch operating mode
(see page 6-39).

Fault Messages 7-7

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Problem 2: If the message accompanying the fault code is “ENERGY SAVER SHUT
DOWN,” the main motor has been turned off by WPC 2000 to save energy. You
will only get this message if you have wired the lockout relay to the motor starter
(see page 2-34) and specified a shutdown time on the Press Control Parameter
Menu in SmartPAC 2 Initialization (see page 4-32).

Remedy 2: Clear the Lockout message, then turn the motor back on to reset the fault. Set the
press to Two-hand Inch operating mode to access Run mode without restarting the
motor. If you continue to get this message, you may need to increase the
Shutdown Time setting.

F11*
Problem: The resolver moved when the output relays to the Dual Safety Valve (DSV) were
off (i.e., open) and the DSV was de-energized.

Remedy: Check clutch, brake and DSV components for correct operation. Correct or repair
any malfunction.

F13
Problem: The Emergency Stop button on the WPC 2000 Operator Station has been
depressed, the E-Stop circuit was open after initiation of the stroke, or the E-Stop
relay circuits are not working properly.

Remedy: If another control is connected to the WPC 2000 E-stop circuit, refer to the user
manual for that control to check for a specific error condition, and correct the
error. If the error persists, contact Wintriss Tech. Support.

F14
Problem: The Prior Act button on the Operator Station was depressed (i.e., switch was open)
after initiation of the stroke.

Remedy: Press RESET. If the problem persists, check the wiring from the Operator Station
to WPC 2000. If necessary, Contact Wintriss Tech. Support.

7-8 Fault Messages

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

F16
Problem: The Top Stop button on the Operator Station was depressed or the Top-stop circuit
was open after initiation of the stroke.

Remedy: Check other equipment (e.g. DiPro 1500, AutoSet, etc.) wired into the Top-stop
string. Correct the problem. Reset the other equipment first; then reset SmartPAC
2 with WPC 2000, and restart the press.

F17
Problem: Cross-checked inputs 8 & 9 were in different states (i.e., open or closed) for longer
than 100 mS.

Remedy: Diagnose and correct the condition that the inputs are monitoring (see Table 7-2,
page 7-15) and reset the connected equipment; then press RESET.

F18
Problem: Cross-checked inputs 10 & 11 were in different states (i.e., open or closed) for
longer than 100 mS.

Remedy: Diagnose and correct the condition that the inputs are monitoring (see Table 7-2,
page 7-15) and reset the connected equipment; then press RESET.

F19 or H19
Problem: Auxiliary E-stop relay did not open properly.

! DANGER
IMPROPER SAFETY SWITCHING RELAY REPAIR
• Replace the Auxiliary E-stop Relay board (see Figure 2-14, page 2-28) before placing the WPC
2000 back into operation after the first occurrence of a fused relay.
If a relay fuses
• DO NOT reset the WPC 2000 to restart the machine.
• Remove the WPC 2000 from operation immediately and replace the Auxiliary E-stop Relay
board before operating the press again.
Failure to comply with these instructions will result in death or serious injury.

Remedy: Press RESET. If the problem persists, contact Wintriss Tech. Support for
assistance or replacement of the relay board,

Fault Messages 7-9

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

F20
Problem: You are attempting to run the main motor in reverse without selecting Two-hand
Inch mode.

Remedy: Select TWO HAND on the Mode Select Menu (see page 6-39), set the Stroke
Select switch to “INCH,” then run the motor in reverse.

F21
Problem: The N/O inputs from the Run/Inch palm buttons on the Operator Station do not
turn off (i.e., open) when they should.

Remedy: Check to make sure that the palm buttons are the correct switch type. Check and
correct the palm switch wiring. If the error persists, call Wintriss Tech. Support.

F22
Problem: The operating mode was changed while the press was running.

Remedy: Make your operating mode selection before running the press.

F23
Problem: The operating mode you selected (i.e., One-hand, Two-hand, or Foot) is not valid
for your stroke selection (i.e., Inch, Single-stroke, or Continuous).

Remedy: Refer to the discussion of operating modes starting on page 6-38 to determine the
correct operating mode for your stroke selection.

7-10 Fault Messages

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

F24
Problem: Both Run/Inch palm buttons on the Operator Station were pressed in One-hand
mode

or

Run/Inch buttons on an unselected Operator Station were pressed in a

dual-Operator-Station setup.

Remedy: Press only one Run/Inch palm button when running the press in One-hand mode

or

Select both Operator Stations in a dual-Operator-Station setup, then initiate a

stroke.

F25
Problem: The flywheel speed sensor is not turning off and on properly while the flywheel is
turning.

Remedy: Check the installation and wiring of the flywheel sensor (see page 2-43), and make
corrections. You can disable flywheel speed sensing by setting the Flywheel
Timer to 0 (zero). See page 4-32 for instructions.

F26
Problem: The flywheel turned faster than 6 SPM while the press was in Bar mode, creating a
potentially unsafe barring condition.

Remedy: After clearing the error, bar the press more slowly. Refer to Operating the Press in
Bar Mode, page 6-52.

F27
Problem: E-stops inputs were in different states (i.e., open or closed) for longer than 100 mS.

Remedy: Check the E-stop circuit wiring and the E-stop buttons.

Fault Messages 7-11

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

F28
Problem: The flywheel was still in motion when the motor was started in the opposite
direction or Bar mode was selected.

Remedy: Press RESET, wait for the flywheel to stop turning, then try again to perform the
desired operation. You may need to set the Flywheel Timer to a lower value (see
page 4-32 for instructions).

F29
Problem: A flywheel sensor is installed, but the Flywheel Timer has been set to 0 (zero),
disabling the sensor.

Remedy: Disconnect the flywheel sensor (see page 2-43), or set the Flywheel Timer to a
value greater than 0 (zero) (see page 4-32).

Inter-processor Failures

F30* through F37*

and
H38* and H39*
Problem: One of the following processor errors has occurred:
F30 Resolver angles for A and B processors disagree by more than 2°
F31 No reply to Check Start request received from second processor
F33 Incorrect reply to Mode Change message received from second processor
F34 No reply to Mode Change message received from second processor
F35 Incorrect reply to Power-up message received from second processor
F36 No reply to Reset Error message received from second processor
F37 No reply to Compare Input Buffers message received from second
processor
H38 Second processor did not receive Power-up information correctly
H39 Second processor did not receive Mode information correctly

Remedy: Try pressing RESET. If error persists, contact Wintriss Tech. Support.

7-12 Fault Messages

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Input Buffer Test Failures

F41* through F44*

Problem: The following errors may occur when WPC 2000 performs input buffer tests,
which compare the input data provided by processor A with the data provided by
processor B. When the input data doesn’t match, an error is generated.
F41 Input buffer 1 check incorrect. This test checks system air pressure and
motor forward inputs and user inputs 1 and 8.
F42 Input buffer 2 check incorrect. This test checks remote reset, motor
reverse, and bar mode selector inputs.
F43 Input buffer 3 check incorrect. This test checks the DSV monitor input and
user inputs 2 and 9.
F44 Input buffer 4 check incorrect. This test checks the motor forward input
and user inputs 2, 5, 7, 8, and 10.

Remedy: Try pressing RESET. If error persists, contact Wintriss Tech. Support.

Air Pressure Limits Exceeded

F45 or H45
Problem: Clutch Air Pressure is below the setpoint established in SmartPAC 2 Initialization.

Remedy: Check your Clutch Air Pressure level. You may need to adjust the Main Air Limit
setting (see page 4-29 for instructions).

F46 or H46
Problem: Counterbalance Air Pressure is outside the Counterbalance Setpoint tolerance
established in SmartPAC 2 Initialization.

Remedy: Check your Counterbalance Air Pressure level. You may need to adjust the
Counterbalance +/- setting (see page 4-29 for instructions).

NOTICE
RAMPAC USERS
This error should not occur if you use RamPAC to monitor Counterbalance Air Pressure.
If you do get this error, make sure that RamPAC is wired correctly to its pressure sensor and that
WPC 2000 is wired correctly to its pressure switch. For pressure switch wiring instructions, refer to
page 2-15. Contact Wintriss Tech. Support if you need further assistance.

Fault Messages 7-13

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Component Failures

F47 and F48

Problem: Failures have occurred to standard equipment connected to WPC 2000.
F47 Dual Safety Valve (DSV) monitor switch input open
F48 Clutch air pressure switch input open

Remedy: Correct the problem, then press RESET. If the error persists, contact Wintriss
Tech. Support.

For F47 errors, try resetting the unit by pressing RESET and turning the Stroke
Select key switch to OFF, then back to one of the other operating modes. If the
DSV continues to fault, check to make sure that the air pressure is not set too low,
and correct if necessary. Also, check to make sure that there are no restrictions in
the air supply line (e.g., restrictive fittings, quick-disconnect fittings, low flow
filters or regulators, or clogged filter elements) and that the supply line is sized to
match the DSV inlet port. If the air pressure and air supply are sufficient, check
for dirt or water in the DSV, and rebuild the valve if necessary.

For F48 errors, check to see whether the air pressure is turned off or set too low,
and correct if necessary. If you are using a pressure sensor instead of a pressure
switch to monitor Clutch Air Pressure, this fault will occur when pin #8 has not
been wired to ground (see step 5 of the Installing a Clutch Air Pressure Sensor
procedure, page 2-14).

Customized Status Codes

NOTICE
You can display the status of user inputs via the F4 (Interlocks) function key on the Display WPC
Input Status screen (see User Interlocks, page 4-24).

F50 through F58

Problem: A failure has occurred in an auxiliary press function (e.g., lubrication system)
wired to a WPC 2000 user input. Refer to Table 7-2, page 7-15 for specific faults.
See also the separate remedies for faults F17, F18, F50, and F58, which apply to
the cross-checked input pairs 8/9 and 10/11.

Remedy: Diagnose and correct the condition that the input is monitoring (see Wiring WPC
2000 User Inputs, page 2-31). If the error persists after you reset the unit, contact
Wintriss Tech. Support.

7-14 Fault Messages

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Table 7-2. Fault Codes for User Inputs

Jumper
User Input Connection
Fault Code (Interlock) Stop Type * Pin # (Bypass)
51 User 1 21 +24 Vdc
52 User 2 82 +24 Vdc
53 User 3 71 +24 Vdc
54 User 4 83 Ground
55 User 5 72 Ground
56 User 6 84 Ground
57 User 7 73 Ground
User 8 paired 85 Ground
with 9
58, 17
User 9 paired 74 Ground
with 8
User 10 paired 86 Ground
with 11 E-stop/
50, 18
User 11 paired Lockout 18 Ground
with 10

* Stop types for all inputs except input pair 10/11 are set to E-Stop by default; input pair 10/11
is set to E-Stop/Lockout. All inputs except input pair 10/11 can be reconfigured by the user.
If you have SmartPAC 2 firmware version 3.32 or higher and WPC 2000 firmware version
1.70 or higher, an additional stop type option, Top-stop/Lockout, is available for user inputs
1-7. To set these inputs to Top-stop/Lockout or to change the stop type setting for any user
input, see page 4-24.

F50
Problem: A failure has occurred in an auxiliary press function wired to WPC 2000
cross-checked input pair 10 and 11 (see Table 7-2). One or both inputs are open.

Remedy: Diagnose and correct the condition that the inputs are monitoring. If the error
persists after you reset the unit, contact Wintriss Tech. Support.

F58
Problem: A failure has occurred in an auxiliary press function wired to WPC 2000
cross-checked input pair 8 and 9 (see Table 7-2). One or both inputs are open.

Remedy: Diagnose and correct the condition that the inputs are monitoring. If the error
persists after you reset the unit, contact Wintriss Tech. Support.

Fault Messages 7-15

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Light Curtain Faults

F60 or H60

-and-

F61 or H61
Problem: Light curtain A (fault #60) or light curtain B (fault #61) failed the WPC 2000
internal test.

Remedy: Check to make sure that the light curtain is wired correctly, referring to figures 4,
14, 15, 20, 21, 23, and 24 at the back of the manual if you have Shadow light
curtains, referring to the appropriate user manual if you have another product. If
you need additional assistance, contact Wintriss Tech. Support.

F62
Problem: Two pairs of light curtains are wired to WPC 2000, but only one pair has been
enabled on option switch 6 on the Press Control Option Switch Menu.

Remedy: Set option switch 6 for dual light curtains (see page 4-38).

F63
Problem: Light curtain A is obstructed during the stroke.

Remedy: Remove the obstruction.

F64
Problem: Light curtain B is obstructed during the stroke.

Remedy: Remove the obstruction.

7-16 Fault Messages

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

F65
Problem: A light curtain is connected with Two-hand Only firmware installed in WPC 2000.

Remedy: Remove the Two-hand Only firmware, and install a firmware version intended for
use with a light curtain, referring to Installing Revised Firmware in WPC 2000,
page 2-85. Contact Wintriss Tech. Support for help in selecting the right firmware
for your application.

Emergency-stop Circuit Driver Failure

F66 or H66
Problem: The Emergency-stop input circuit driver has failed or is about to fail.

Remedy: Check E-stop circuit wiring, and correct any problems. If the error persists after
you reset the unit, contact Wintriss Tech. Support for assistance or replacement of
the driver.

Top-stop Circuit Driver Failure

F67 or H67
Problem: The Top-stop input circuit driver has failed or is about to fail.

Remedy: Check Top-stop circuit wiring, and correct any problems. If the error persists after
you reset the unit, contact Wintriss Tech. Support for assistance or replacement of
the driver.

Fault Messages 7-17

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Shadow Light Curtain Input Faults

F68 or H68

-and-

F69 or H69
Problem: Shadow light curtain A (fault #68) or B (fault #69) inputs to WPC 2000 are not in
the same state (i.e., one input is “on,” the other is “off”).

Remedy: Check “Light curtain A1 input” and “Light curtain A2 input” LEDS on the WPC
2000 Main Processor board if light curtain A is generating the fault, or check
“Light curtain B1 input” or “Light curtain B2 input” LEDs if light curtain B is
generating the fault (see Figure 2-41, page 2-89).

If one of the two LEDs is unlit, receiver wiring is bad or one of the receiver outputs
may be shorted. Check the wiring at the receiver and correct if necessary.

If the wiring is good, either the receiver needs to be replaced, or there is a problem
with WPC 2000. Contact Wintriss Tech. Support for assistance.

7-18 Fault Messages

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

DSV Interface and Lockout Relay Failures

F70* through F78*

- or -

H72* through H76*

! DANGER
IMPROPER SAFETY SWITCHING RELAY REPAIR
• Replace the DSV/Lockout Relay board (see Figure 2-14, page 2-28) before placing the WPC
2000 back into operation after the first occurrence of a fused relay.
If a relay fuses
• DO NOT reset the WPC 2000 to restart the machine.
• Remove the WPC 2000 from operation immediately and replace the DSV/Lockout relay board
before operating the press again.
Failure to comply with these instructions will result in death or serious injury.

Problem: The following errors indicate failures on the WPC 2000 Main Processor board or
the DSV/Lockout Relay board. Error codes F70, F71, F72/H72, F73/H73, and
F76/H76 indicate failures with the DSV driver logic on the Main Processor board.
Codes F74/H74, F75/H75, and F77 indicate failures with the relays on the DSV/
Lockout Relay board. F78 indicates an issue with the poppet position sensors in
the DSV valve itself.
F70 DSV relay driver A was not off at start of stroke
F71 DSV relay drivers A and B did not turn on properly or have shorted
F72 or H72 DSV Control Flip-flop is not functioning properly
F73 or H73 DSV Missing Pulse Detector window is not functioning properly
F74 or H74 DSV relay A or B did not close properly at start of stroke
F75 or H75 DSV relay A or B did not open properly at end of stroke
F76 or H76 Lockout relay driver did not turn on properly during testing
F77 Lockout relay check contacts were not closed before lockout relay
was turned on
F78 The position of the DSV poppets is incorrect (Minster version only).

Remedy: Press RESET. If the error persists, contact Wintriss Tech. Support for assistance
or replacement of either board.

Fault Messages 7-19

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Loss of Rotation

F79
Problem: The Dual Safety Valve (DSV) has been activated, but the resolver did not start
rotating within the Start-time Limit set on the Press Control Parameter Menu (see
page 4-31).

The Start-time Limit setting may be too short. Alternatively, the drive belt on the
resolver may be loose or broken, and the resolver may not be turning continuously
with the press crankshaft, or have stopped turning altogether. Also, the resolver
may be defective.

Air pressure to the clutch may be low, or the clutch may be bad, resulting in no
movement of the crankshaft (and resolver) even though the DSV is energized. In
addition, an internal WPC 2000 problem could have occurred.

Remedy: Check the Start-time Limit setting, and increase if necessary. Check the resolver
and resolver drive, and replace the resolver if necessary. Check the clutch and
repair if necessary. If these solutions do not work, contact Wintriss Tech. Support.

Internal Timing Input Failures

F80 or H80

- and -

F82 or H82
Problem: There is an internal problem with the WPC 2000 timing inputs.

Remedy: Press RESET. If the error persists, contact Wintriss Tech. Support for assistance
or replacement of the timing inputs.

7-20 Fault Messages

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Top-stop and Overrun Setting Faults

F81, F83, F84, F86 and F87

- and -

H81, H83, H84, H86 and H87

Problem: The overrun limit switch has turned on before the Top-stop “On” Angle timing has
turned off. The Top-stop Angle internal dwell is 20°.

Remedy: Check to make sure that the Top-stop “On” Angle has been set correctly (see
page 2-79) and that the overrun sensor magnet has been installed at the correct
angle (see page 2-82). If settings are correct and the error persists, contact
Wintriss Tech. Support.

Overrun Limit Switch Fault

F85
Problem: The overrun limit switch has provided more than one signal to WPC 2000 during a
stroke. The switch should open and close only once per stroke.

Remedy: Check the overrun limit switch installation to make sure that the switch opens and
closes only once per stroke, referring to Installing the Overrun Sensor Magnet,
page 2-82 and the LED map on page 2-89. Check to make sure that the switch is
installed correctly, referring to page 2-29, and that the magnet is installed at the
correct angle (see page 2-82). Also, check to make sure that the magnet is attached
using a brass or other non-ferrous screw.

Check the diameter of the shaft on which the magnet is mounted to make sure
there is enough dwell for the overrun limit switch to provide an adequate signal
(see Planning Your Overrun Sensor Installation, page 2-29). An ideal diameter is
4 in. to 6 in. If the shaft is larger than this, mount the magnet on a shaft with a
smaller diameter.

Check to make sure that the press is not encountering excessive shock and
vibration due to operations such as blanking. If you cannot resolve the problem,
contact Wintriss Tech. Support.

Fault Messages 7-21

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Overrun Limit Switch Test Angle Fault

F88 or H88
Problem: The overrun limit switch was not closed during the overrun sensor closure test
window (see step 2, page 2-83) or open at 180°.

Remedy: The resolver drive may have slipped or broken. If this is the case, the resolver
needs to be repaired or replaced. If the resolver drive checks out, also check the
wiring and installation of the resolver (see Installing the Resolver, page 2-24).

Check the diameter of the shaft on which the magnet is mounted to make sure
there is enough dwell for the switch to provide an adequate signal (see Planning
Your Overrun Sensor Installation, page 2-29). An ideal diameter is 4 in. to 6 in. If
the shaft is larger than this, mount the magnet on a shaft with a smaller diameter.

Check installation of the overrun sensor and magnet and wiring of the overrun
sensor, referring to Installing the Overrun Limit Switch, page 2-29 and Installing
the Overrun Sensor Magnet, page 2-82.

Overrun Limit Switch Setting Fault

F89 or H89
Problem: The angle range (e.g., 271° to 300°) within which the Top-stop “On” Angle must
fall has not been set correctly on option switches 1 and 2 on the Press Control
Option Switch Menu.

Remedy: Set switches 1 and 2 for the correct Top-stop “On” Angle window, referring to
Table 2-26, page 2-82. If the error persists, contact Wintriss Tech. Support.

7-22 Fault Messages

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Internal Memory Failures

F90* through F98*

- or -

H90* through H98*

Problem: There is a problem with the main or second processor on the WPC 2000 Main
Processor board. The board may need to be serviced or replaced. Errors are as
follows:
F90 or H90 Program memory checksum 1 is incorrect
F91 or H91 Program memory checksum 2 is incorrect
F95 or H95 Angle table memory checksum is incorrect
F96 or H96 RAM memory failed memory test
F97 or H97 No angle setup is loaded
F98 or H98 The option switch image changed during operation
F99 or H99 +24 Vdc failed, or the fuse blew

Remedy: Press RESET. If the error persists, contact Wintriss Tech. Support for assistance
or replacement of the Main Processor board or firmware chip.

Counter Preset Reached Messages

“Good parts counter preset reached”

Problem: The value set for the parts counter has been reached. The press should stop at top
dead center.

Remedy: 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.

Fault Messages 7-23

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

“Strokes counter preset reached”

Problem: The value set for the strokes counter has been reached. The press should stop at
top dead center.

Remedy: 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”

Problem: 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.

Remedy: Press RESET to clear the message.

NOTICE
When this message appears, the corresponding batch count is automatically reset to 0.

Messages for Equipment or Brake Monitor Problems

The following messages cover resolver and input circuit faults, problems with the way the
press is running, brake monitor faults, and internal problems with SmartPAC 2.

“Loss of rotation detected”

Problem: The resolver did not start rotating within the start time limit set in Initialization
(see page 4-31) or stopped rotating while the press was running.

SmartPAC 2 knows when the Dual Safety Valve (DSV) is energized. If it sees that
the DSV is energized but the resolver is not turning, this message appears.

One possible cause is that the resolver’s drive belt is loose or broken. Another is
that you may have low air pressure to the clutch or a bad clutch. An internal
SmartPAC 2 problem could also have occurred, or the resolver could be defective.

Remedy: Check the resolver, the resolver drive, and the clutch. Repair if necessary. If these
solutions do not work, an internal problem may have occurred. Call Wintriss
Tech. Support.

7-24 Fault Messages

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

“Angle Resolver Failure”

Problem: The wiring in the resolver circuit to SmartPAC 2 may be loose or bad, or the
resolver may have failed. Another possible cause is that the press may be going
faster than 800 SPM (or 1600 SPM, depending on the speed setting in SmartPAC
2).

Remedy: Check the resolver wiring and connections for shorts, breaks, or loose connections
(see Wiring the Resolver, page 2-25). If SmartPAC 2’s rated press speed has been
exceeded, reduce the speed. If the speed hasn’t been exceeded, make sure that the
speed has been set correctly (see Setting Up High-speed Version of SmartPAC 2
with WPC 2000, page 2-70). If these remedies do not correct the problem, the
resolver may need to be replaced. Contact the factory for assistance.

NOTICE
To clear this fault, you must power down SmartPAC 2, then power the unit back up.
Pressing RESET does not work.

“Input check circuit failure”

Problem: The resolver turned five times, indicating that the press was running, but
SmartPAC 2 received no signal from the input check circuit. The input check
circuit may not have been connected or wired properly. If this message occurs
when the press stops, the brake may be worn.

Remedy: Check the wiring of the input check circuit and rewire, if necessary, following the
instructions in Connecting Stop Circuits and Input Check Circuit, page 2-54.
Make sure the input check voltage switch (S101) is set correctly, as shown in
Figure 2-27, page 2-55. If the input check circuit is not the problem, check your
brake for wear.

E-Stop errors

Problem: If the word “ESTOP” appears in a message, one or both of the emergency stop
relay circuits is 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.

Fault Messages 7-25

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

“Inboard ram test failure”

Problem: Something is wrong with the SmartPAC 2 main processor board. The board may
need to be serviced or replaced.

Remedy: 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.

“Resolver signals incorrect” or “Resolver drive signal incorrect”

Problem: There is a problem with the resolver assembly.

Remedy: Check to make sure that the Master/Slave jumper, JP101, on the SmartPAC 2
board (see Figure 2-25, page 2-51) is set to the following position:
• MASTER for a SmartPAC 2 without WPC Clutch/Brake control
integration
• SLAVE for a SmartPAC 2 with WPC Clutch/Brake control integration

Check the resolver and wiring. Make sure that the terminals are tightened on bare
wire and not on insulation (see Connecting the Resolver Wiring, page 2-50). If
necessary, contact Wintriss Tech. Support for assistance or replacement of the
resolver.

“Stop time exceeded”

Problem: The stopping time of the press has exceeded the limit set in SmartPAC 2
Initialization. You should have been pre-warned of this condition by the brake
warning LED, which flashes whenever the stopping time is within 10 milliseconds
of the stop-time limit.

This message displays when the stop-time limit is not sufficient to allow for
normal brake wear, or the brake is excessively worn and needs servicing. If the
brake is worn, a dangerous safety problem may exist and should be corrected
immediately.

Remedy: First, perform several 90° stop-time test runs to get an actual reading for your
press’s stop time. Compare these results with the results you got the last time you
performed the test. Decide if the current stop-time limit is realistic or needs to be
changed slightly. See page 4-31 to calculate the correct stop-time limit and
page 6-22 to perform the 90° stop-time test. If you change the limit, you may have
to relocate your light curtains and/or two-hand controls. Refer to the appropriate
manual for assistance.

If the brake is worn, you should have your maintenance personnel service the
brake immediately.

7-26 Fault Messages

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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”

Problem: 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.

“Tool number table checksum error”

Problem: 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.

Fault Messages 7-27

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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.

Messages for Sensor Faults

“Green sensor missed”

Problem: A green or green quick check sensor did not turn on during the Ready signal nor
within 50 milliseconds after the Ready signal. No stroke angle is displayed for this
error since the sensor never turned on.

Remedy: 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”

Problem: A green or green quick check sensor turned on late, that is, 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, 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”

Problem: 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.

7-28 Fault Messages

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

“Green constant fault”

Problem: A green constant sensor was not on at the beginning of its Ready signal or turned
off during the Ready signal. Green constant sensors must stay on throughout the
Ready signal. The angle at which the sensor turned off is displayed.

Remedy: 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”

Problem: 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”

Problem: 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 5-29.

Fault message for yellow sensors: “This N/O sensor is grounded”

Problem: 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.

Fault Messages 7-29

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Fault message for red sensors: “This N/C sensor is open”

Problem: 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

“Maximum press speed exceeded”

Problem: The press is running at a speed greater than the maximum limit programmed for
this tool.

Remedy: After clearing the error, either run the press at a slower speed, or adjust the limit
set in Program mode (see PRESS CONTROL, page 5-48).

“Minimum press speed exceeded”

Problem: The press is running at a speed less than the minimum limit programmed for this
tool.

Remedy: After clearing the error, either run the press at a higher speed, or adjust the limit
set in Program mode (see PRESS CONTROL, page 5-48).

“The resolver position is different from when the unit was turned off”

Problem: This message will only appear if SmartPAC 2 detects that the resolver angle when
the press is turned on is different from the angle when the press was turned off.
This can happen when you move the press or upgrade SmartPAC 2 firmware.

Remedy: Press RESET to clear. If the message reappears, call Wintriss Tech. Support.

“One of the sensor auto enable counters is greater than 99”

Problem: 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.

Remedy: First press RESET. If the message reappears, contact Wintriss Tech. Support.

7-30 Fault Messages

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

“Loss of Communication at Address X”

Problem: SmartPAC 2 is unable to communicate with the optional module identified by “X”
in the message (see Table 7-3).

Remedy: Check the wiring of the specified module. If you continue to get this error
message, call Wintriss Tech. Support.

Table 7-3. Communication Errors: Option at Fault

Message Option Identified by Address
Loss of Communication at Address 1 AutoSetPAC or WaveFormPAC
Channels 1 - 4
Loss of Communication at Address 2 AutoSetPAC or WaveFormPAC
Channels 5 - 8
Loss of Communication at Address 4 RamPAC
Loss of Communication at Address 5 ProPAC

“File Not Found”

Problem: 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 I-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 6-33 and Sending E-mail to Wintriss Technical Support, page 6-37 for
more information.

Resetting Ross DM2 DSV Faults

If your Ross DM2 DSV faults when air is first applied to the unit, one or both poppets may
have been jarred into a faulted position during shipment. When the poppets are faulted, input
air can escape through the muffler port. To reset the fault, air must be applied to DSV to
return the poppets to their unfaulted position.
If the fault occurs before the unit has been wired, the problem will be signalled by air escaping
from the muffler port when input air is applied to the DSV. To reset the unit, press the brass
button on the bottom of the Reset solenoid while air is being applied to the DSV (see
Figure 7-4, page 7-32).

Fault Messages 7-31

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Figure 7-4. Ross DM2 DSV Showing Reset Button

If the fault occurs after the unit has been wired, an F47 error will appear on the SmartPAC 2
display. To clear the fault and reset the DSV, press RESET and turn the Stroke Select key
switch to OFF, then to one of the other operating modes (see page 7-14).
If you have trouble resetting the DSV, the problem may be that both poppets are faulted,
requiring more air for a reset than can be supplied by the system. In this case, try resetting the
unit with the muffler port obstructed. Place your hands or a rag or plastic packaging material
over the muffler to restrict the escape of air, then actuate the Reset solenoid.
If the DSV still will not reset, check to see if there are restrictions in the air supply line (e.g.,
restrictive fittings, quick-disconnect fittings, low flow filters or regulators, or clogged filter
elements) and correct if necessary. Also, check to make sure that the air supply line matches
the inlet port size of the DSV, and replace with a properly-sized supply line if it doesn’t.

7-32 Fault Messages

Appendix A. Extracts from OSHA
Regulations and ANSI Standards
! WARNING
REFER TO CURRENT REVISIONS OF OSHA/ANSI DOCUMENTS
The following extracts from OSHA and ANSI documents are provided for the user’s convenience
only. Refer to the most recent revisions of the original OSHA safety regulations and ANSI
standards to ensure that you have the most up-to-date information.
Failure to comply with these instructions could result in death or serious injury.

This appendix provides extracts from the Occupational Safety and Health Administration
(OSHA) regulations and the American National Standards Institute (ANSI) standards
covering presence-sensing devices.

Extracts from OSHA Regulation 1910.217

! WARNING
REFER TO CURRENT REVISIONS OF OSHA/ANSI DOCUMENTS
The following extracts from OSHA and ANSI documents are provided for the user’s convenience
only. Refer to the most recent revisions of the original OSHA safety regulations and ANSI
standards to ensure that you have the most up-to-date information.
Failure to comply with these instructions could result in death or serious injury.

Reprinted below are extracts from OSHA regulation 1910.217 pertaining to the use of
presence-sensing devices for point-of-operation guarding on mechanical power presses. Also
reprinted here are interpretations of selected regulations provided by the Precision
Metalforming Association (PMA). Extracts from the OSHA regulation are printed in the left-
hand column; interpretations by PMA are shown in the right-hand column.
Wintriss makes no claim for the accuracy or effectiveness of the PMA interpretations, and
persons making use of this material do so at their own risk. PMA interpretations should not be
relied upon for use in any specific application. The material is provided, with PMA’s
permission, for informational purposes only.
Refer to the most recent versions of OSHA documents. To obtain copies of OSHA
regulations, write to: OSHA’s Office of Information and Consumer Affairs, 200 Constitution
Avenue NW, Room N3647, Washington, DC 20210. Tel (202) 219-8151; fax (202) 219-
5986.

Extracts from OSHA and ANSI A-1

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Extracts from OSHA Regulation 1910.217

OSHA Regulations PMA Interpretation
OSHA 1910.217 (c). TABLE 0-10
(c) SAFEGUARDING THE POINT OF Distance of opening Maximum width of
OPERATION. from point of operation opening (inches)
hazard (inches)
(1) General requirements.
1/2 to 1 1/2 . . . . . . . . . . . . . . . . . . . . 1/4
(i) It shall be the responsibility of the 1 1/2 to 2 1/2 . . . . . . . . . . . . . . . . . . . . 3/8
employer to provide and insure the usage 2 1/2 to 3 1/2 . . . . . . . . . . . . . . . . . . . . 1/2
of “point of operation guards” or properly 3 1/2 to 5 1/2 . . . . . . . . . . . . . . . . . . . . 5/8
applied and adjusted point of operation 5 1/2 to 6 1/2 . . . . . . . . . . . . . . . . . . . . 3/4
devices on every operation performed on a 6 1/2 to 7 1/2 . . . . . . . . . . . . . . . . . . . . 7/8
mechanical power press. See Table 0-10. 7 1/2 to 12 1/2 . . . . . . . . . . . . . . . . . . . 1 1/4
12 1/2 to 15 1/2 . . . . . . . . . . . . . . . . . . . 1 1/2
15 1/2 to 17 1/2 . . . . . . . . . . . . . . . . . . . 1 7/8
17 1/2 to 31 1/2 . . . . . . . . . . . . . . . . . . . 2 1/8
OSHA 1910.217 (c) (3) (i) (a)
(3) Point of operation devices. Presence-sensing device
(i) Point of operation devices shall protect the
operator by:
(a) Preventing and/or stopping normal (c) (3) (i) (a) Refers to the functional
stroking of the press if the operator’s hands requirement of a presence-sensing device
are inadvertently placed in the point of which prevents and/or stops normal stroking of
operation. the press.
OSHA 1910.217 (c) (3) (iii)
(iii) A presence-sensing point of operation
device shall protect the operator as provided
in paragraph (c) (3) (i) (a) of this section, and
shall be interlocked into the control circuit to
prevent or stop slide motion if the operator’s
hand or other part of his body is within the
sensing field of the device during the
downstroke of the press slide.
(a) The device may not be used on
machines using full revolution clutches.
(b) The device may not be used as a European method (curtain of light) uses self trip
tripping means to initiate slide motion. safety system effectively. Variance applied for
11/17/73 by Interlake Stamping Company to use
this fail safe system.
(c) The device shall be constructed so that When failure occurs, the best indication is the
a failure within the system does not prevent press won’t run.
the normal stopping action from being
applied to the press when required, but
does prevent the initiation of a successive
stroke until the failure is corrected. The
failure shall be indicated by the system.

A-2 Extracts from OSHA and ANSI

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Extracts from OSHA Regulation 1910.217

OSHA Regulations PMA Interpretation
(d) Muting (bypassing of the protective Top of stroke is the point at which muting shall
function) of such device, during the cease as it is not possible to set a point on the
upstroke of the press slide, is permitted for downstroke as the exact position where the
the purpose of parts ejection, circuit hazard of die closing starts.
checking and feeding.
(e) The safety distance (Ds) from the Safety distance represents the distance an
sensing field to the point of operation shall operator can move his hand during the time it
be greater than the distance determined by takes a press to stop. The internationally
the following formula: recognized hand reach speed is 63 inches/
second.
Ds = 63 inches/second x Ts, where To determine this safety distance, the stopping
time of the press is measured with some
Ds = minimum safety distance (inches); appropriate measuring device. The
63 inches/second = hand speed constant; measurement is taken such that the stop signal
is given to the press at the 90 degree point of
and the crank position.
Ts = stopping time of the press measured Since some stopping time increase must be
approximately 90° position of crankshaft accommodated due to braking system
rotation (seconds). deterioration, a percentage factor must be
added to the measured time to obtain the factor
for use in the equation for determining safety
distance. A percentage factor of 20% is
recommended for presses with new brakes or
brakes of good condition. For older brakes, a
10% factor is recommended.
Example:
Measured stopping time = 0.190 seconds
Time factor = 1.2 x 0.19 = 0.228 seconds
Calculation = 63 x 0.228
Safety distance = 14.4 inches
(f) Guards shall be used to protect all areas (3) (iii) (f) Great care must be taken to assure
of entry to the point of operation not that no access to the die area exists unguarded.
protected by the presence-sensing device.
OSHA 1910.217 (c) (3) (5) This paragraph tells the condition under which a
brake monitoring system is required after
(5) Additional requirements for safe-guarding.
November 1, 1975.
Where the operator feeds or removes parts by
placing one or both hands in the point of
operation, and a two hand control, presence-
sensing device, Type B gate or movable barrier
(on a part revolving clutch) is used for
safeguarding:
(i) The employer shall use a control system
and brake monitor which comply with
(b) (13) Control reliability
paragraphs (b) (13) and (14) of this section.
This requirement should be complied with by (b) (14) Construction requirements.
November 1, 1975.

Extracts from OSHA and ANSI A-3

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Extracts from OSHA Regulation 1910.217

OSHA Regulations PMA Interpretation
OSHA 1910.217 (c) (3) (vii) (c)
(c) The safety distance (Ds) between each
two hand control device and the point of
operation shall be greater than the distance
determined by the following formula:

Ds = 63 inches/second x Ts, where Example:

Ds = minimum safety distance (inches); Measured stopping time = 0.190
Time factor = 1.2 x 0.19 x = 0.228 seconds
63 inches/second = hand speed constant; Calculation = 63 x 0.228
and Safety distance = 14.4 inches
Ts = stopping time of the press measured
approximately 90° position of crankshaft
rotation (seconds).
OSHA 1910.217 (e) (1)
(e) INSPECTION, MAINTENANCE, AND
MODIFICATION OF PRESSES
(i) It shall be the responsibility of the Records of clutch and brake will be weekly.
employer to establish and follow a program of Other inspections are periodic subject to time
periodic and regular inspections of his power factor determined by employer.
presses to insure that all their parts, auxiliary
equipment, and safeguards are in safe
operating condition and adjustment. The
employer shall maintain records of these
inspections and the maintenance work
performed.
(ii) Each press shall be inspected and tested If brake monitoring system is installed, weekly
no less than weekly to determine the inspection and records are not required for
condition of the clutch/brake mechanism, anti- clutch/brake mechanism. Other parts of the
repeat feature and single stroke mechanism. press will require periodic inspections and
Necessary maintenance or repair or both records.
shall be performed and completed before the
press is operated. The employer shall
maintain records of these inspections and the
maintenance work performed. These
requirements do not apply to those presses
which comply with paragraphs (b) (13) and
(14) of this section.

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Extracts from ANSI Standards for Presence-sensing

Devices and Two-hand Controls
! WARNING
REFER TO CURRENT REVISIONS OF OSHA/ANSI DOCUMENTS
The following extracts from OSHA and ANSI documents are provided for the user’s convenience
only. Refer to the most recent revisions of the original OSHA safety regulations and ANSI
standards to ensure that you have the most up-to-date information.
Failure to comply with these instructions could result in death or serious injury.

Reprinted below are the American National Standards Institute (ANSI) standards for
presence-sensing devices (light curtains) and Two-hand controls. ANSI, a national federation
of trade associations, technical societies, professional groups, and consumer organizations, is
the United States clearinghouse and coordinating body for voluntary standards activity.
Approximately 1000 companies are affiliated with the Institute as company members.
ANSI creates voluntary standards to eliminate duplication and to weld conflicting standards
into single, nationally accepted standards under the designation “American National
Standards.” The standards reflect a national consensus of manufacturers, consumers,
scientific, technical, and professional organizations, and governmental agencies.
Shown below are extracts of standards requirements and explanatory information from ANSI
B11.1-2009 and B11.19-2003 for presence-sensing devices (light curtains) and Two-hand
controls. Complete versions of these documents can be obtained by writing to: ANSI, 1430
Broadway, New York, NY 10018.

Extracts from OSHA and ANSI A-5

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Extracts from ANSI B11.1-2009 8.6.2.1

Standards Requirements Explanatory Information
8.6.2.1.7 Each operator’s hand controls shall be E8.6.2.1.7 The total stopping time of the press
located at a distance from the point-of-operation should include the total response time of the
so that the operator(s) cannot release either control system and the time it takes hazardous
hand actuating control and reach into the point- motion to stop. The following formula should be
of-operation during the hazardous portion of the used when calculating the safety distance (Ds):
cycle.
Ds = K (Ts + Tc + Tbm)
Where:
K = 63 inches/second (hand speed constant).
Ts = the stop time of the press measured from
the final de-energized control element, usually
the air valve.
Tc = the response time of the control.
Tbm = the additional time allowed by the
stopping-performance monitor (brake monitor)
before it detects stop time deterioration.
NOTE – Ts + Tc are usually measured by a stop
time measuring device.
When the press stopping-performance monitor
setting is changed, the safety distance should
be recalculated. See also Annex C.

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Extracts from ANSI B11.1-2009 8.6.3

Standards Requirements Explanatory Information
8.6.3 Presence-sensing safeguarding device
8.6.3.1 A presence-sensing device, when used E8.6.3.1 Various presence-sensing devices
for safeguarding, shall protect the operator as employ different sensing and adjustment
specified in E8.6.1 (a). techniques. The point at which a device
responds to an intrusion can vary.
Safety mats and area scanners may not be
suitable (effective) safeguards when utilized as
primary point-of-operation safeguarding.
Factors which can affect this suitability include
but are not limited to:
a) response time;
b) minimum object sensitivity;
c) measurement accuracy;
d) breach ability;
e) penetration before detection;
f) single point of failure;
g) large safety distances.
These devices may be utilized as supplemental
safeguarding.
8.6.3.2 The device shall be interfaced with the E8.6.3.2 The device should be located or
control circuit to prevent or stop slide motion if adjusted so that the device always responds to
any object is within the sensing field of the the intrusion at or prior to the safety distance Ds.
device during the hazardous portion of the
cycle. Also, care should be taken when installing the
device so that it does not detect false signals
from other devices or equipment in the area.
The presence-sensing device cannot protect
against a catastrophic failure of the press, which
causes unintended cycling action. See Annex A,
Figure A.3.
8.6.3.3 The device shall not be used for
safeguarding the point-of-operation on presses
using full-revolution clutches.
8.6.3.4 When the sensing field has been
interrupted, use of the normal press cycle-
actuating means shall be required after clearing
the sensing field to resume press operation.
8.6.3.5 When the device is used in the PSDI
mode, re-initiation of the press motion shall be in
accordance with 6.4.3.8.1.
8.6.3.6 Muting of the device shall be permitted E8.6.3.6 Muting is typically accomplished by
only during the non-hazardous portion of the interface circuits or auxiliary controls.
press cycle.
The die closing portion of the cycle is always
considered hazardous. In some cases, feeding
and transfer automation or die features can
cause additional hazardous conditions even
during the opening portion of the cycle
(upstroke). See also B11.19 for additional
information.

Extracts from OSHA and ANSI A-7

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Extracts from ANSI B11.1-2009 8.6.3

Standards Requirements Explanatory Information
8.6.3.7 Muting of the device shall be E8.6.3.7 Muting is typically accomplished by
accomplished in a manner that conforms to the interface circuits or auxiliary controls. The
requirements of 6.11 and 8.8. muting element should incorporate a similar
level of control reliability as the presence-
sensing device itself. A simple cam-operated
limit switch wired in parallel with the device’s
output is inadequate, as its failure can remain
undetected.
8.6.3.8 The device shall have an identifiable E8.6.3.8 The device should have a minimum
minimum object sensitivity so that an obstruction object sensitivity stated by the device supplier.
of an equal or greater size will be detected For example, an electro-optical device may
anywhere within the sensing field regardless of detect a 32 mm (1¼ inch) diameter opaque
the plane of intrusion. object anywhere in its sensing field but allow 25
mm (1 inch) obstructions to pass undetected at
certain points in the field.
8.6.3.9 The device shall have a maximum E8.6.3.9 The device supplier should state the
response time, which shall not be affected by maximum total response time, including output
object sensitivity adjustments or environmental devices, of the presence-sensing device.
changes.
8.6.3.10 Devices which require adjustments to E8.6.3.10 Typically, these adjustments or
accommodate variations in operating conditions, controls are key-operated or located under
or which incorporate fixed blanking or floating lockable covers.
blanking features, shall be designed so that the
adjustments or features are capable of
supervisory control by the user.
8.6.3.11 The device shall be provided with a E8.6.3.11 Red and green indicators or other
means that visibly indicates when it is means that can be easily seen by the operator
functioning properly. and others should be provided to indicate that
the device is functioning.
Indication that the sensing field is being blanked The blanking function of a presence-sensing
shall be provided. For fixed blanking, the safeguarding device desensitizes a portion of
blanked area shall be identified. Supplemental the sensing field by disabling one or more
safeguarding shall be provided to prevent channels such that a specific interruption is
access to the hazard through the fixed blanked ignored. Presence-sensing devices can be
area. provided with either fixed or floating blanking.
For fixed blanking, the desensitized area does
not move or change once configured. Floating
blanking allows the blanked area to move within
the sensing field.
Means to identify the desensitized area may
include but are not limited to:
a) Indicators within the device;
b) Signage or marking of the fixed blanked
area;
c) The physical location of the object in the
blanked area if movement or removal of
the object can be detected and it results in
a stop command.

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Extracts from ANSI B11.1-2009 8.6.3

Standards Requirements Explanatory Information
8.6.3.11 (cont) Means of supplemental safeguarding can
include completely filling the fixed blanked area
to restrict access to the hazard, installing the
device at a distance that accounts for the worse
case object sensitivity (see 8.6.3.16), or
alternate safeguarding may be provided to
prevent access to the hazard.
If means are provided to bypass the device, Means to provide visible indication may include
visible indication that the device is bypassed but are not limited to:
shall be provided.
a) colored indicator lights;
b) signage;
c) physical position;
d) awareness barrier (i.e., safety tape);
e) other means.
8.6.3.12 The device shall not fail to respond to
the presence of the individual’s hand or other
body part due to the presence of a reflective
object or workpiece.
8.6.3.13 The device shall conform to the
requirements of 6.11 and 8.8. In the event of a
power failure to the device, the device shall
initiate a stop command to the press control
system.
8.6.3.14 The interface of the presence-sensing
device to the press control shall conform to the
requirements of 6.11 and 8.8.
8.6.3.15 The sensitivity of the device to
intrusion shall not be adversely affected by
changing conditions around the press.
8.6.3.16 The effective sensing field of the E8.6.3.16 The total stopping time of the press
device shall be located at distance from the should include the total response time of the
nearest point-of-operation hazard so that presence-sensing device, as stated by the
individuals cannot reach into the point-of- supplier, the response time of the interface, the
operation with a hand or other body part before response time of the control system, and the
cessation of motion during the hazardous time it takes the press to cease slide motion.
portion of the cycle.
The following formula should be used when
calculating the safety distance:
Ds = K (Ts + Tc + Tr + Tbm) + Dpf
where
K = 63 inches/second (hand speed constant)
Ts = the stop time of the press measured from
the final de-energized control element, usually
the air valve
Tc = the response time of the press control
Tr = the response time of the presence-sensing
device and its interface, if any, as stated by the
supplier or measured by the user.

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Extracts from ANSI B11.1-2009 8.6.3

Standards Requirements Explanatory Information
8.6.3.16 (cont) Tbm = the additional stopping time allowed by
the stopping-performance monitor before it
detects stop time deterioration.
Dpf = the added distance due to the penetration
factor as recommended in ANSI B11.19, Annex
D, Figure D.2. The minimum object sensitivity is
stated by the supplier. If beam blankouts or
floating window features are used, these figures
should be added to the object sensitivity figure
before using the chart.
NOTE - Ts + Tc is usually measured by a stop
time measuring device. See also ANSI B11.19,
Annex C and D.
Whenever the press-cycle STOP command or
stopping-performance monitor time or angle
setting is changed, the safety distance should
be recalculated. See also “stopping-
performance monitor” (6.12).
NOTE – No increase in safety distance is
required for fixed blanking applications if the
blanked area is entirely occupied by the material
or fixtures.
In some instances, the use of blanking does not
allow efficient production of certain piece parts.
Horizontal placement of the sensing field, so
that it detects that operator’s waist area, may
present a solution. In this application, the
operator may freely manipulate the workpiece
and operate the press as long as the operator
stands outside of the horizontal sensing field.
The sensing field should be located so that the
operator cannot reach the point-of-operation
prior to interrupting the sensing field and
completion of the stopping action. Where
possible, the sensing field should be of sufficient
depth to prevent the operator from standing
between the field and the point-of-operation.
See also ANSI B11.19, Annex C and D.

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Extracts from ANSI B11.1-2009 8.6.3

Standards Requirements Explanatory Information
8.6.3.17 If the position of the device will allow E8.6.3.17 Additional means may include
the operator or others to place themselves manual reset outside of the sensing field of the
between the sensing field and the point-of- device or additional barrier guards, safety mats,
operation, additional means shall be provided in light curtains, or other devices.
conjunction with the device to prevent the
operator or others from exposure to the point-of- Operator controls for each operator located
outside of the sensing field of the presence-
operation hazard.
sensing device may be used.
As an alternative to the reset control and to
prevent an individual from stepping behind the
sensing field of a PSD, the maximum distance
between the light curtain and the machine
structure should not exceed 75mm (3 inches).
Supplemental safeguarding may be utilized to
eliminate a space greater than 75mm.
8.6.3.18 The device shall not be affected by E8.6.3.18 Examples of ambient light are
ambient light or by light-source decay so that the associated with windows, light fixtures,
increase in response time or object sensitivity is skylights, bay doors, or die lights.
greater than the value used to calculate the
safety distance.
8.6.3.19 All areas of entry to the point-of- E8.6.3.19 Usually the electro-optical presence-
operation not protected by the presence- sensing devise is used in a manner that
sensing device shall be otherwise safeguarded. provides a protected zone in front of the primary
work area with auxiliary devices or guards used
to protect secondary access areas.
In some cases, mirrors may be used in
conjunction with the device to provide two-,
three- or four-sided protection.
8.6.3.20 Press production systems with a E8.6.3.20 For PSDI applications see Clause 10.
configuration that would allow an individual to
enter, pass through, and become clear of the
presence-sensing device sensing field shall not
be operated in the PSDI mode of operation.
8.6.3.21 When a device is used on a press
production system and the protection of the
operator is dependent upon the stopping action
of the press, a stopping-performance monitor
shall be required in conformance with 6.12. See
section 8.3.9 for exceptions.

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Extracts from ANSI B11.19-2003 8.3

Standards Requirements Explanatory Information
8.3 Electro-optical, RF, and area
scanning presence-sensing
safeguarding devices
8.3.1 Design and construction
8.3.1.1 The presence-sensing device shall be E8.3.1.1 The device should be designed and
designed and constructed to create a field that constructed such that it does not present
detects the presence of an individual(s). hazards to individuals from:
The presence-sensing device shall not create a sharp edge or pinch point hazards;
hazard in and of itself. radiated light or energy hazards;
electromagnetic interference hazards;
electrical shock hazards.
8.3.1.2 The electro-optical presence-sensing E8.3.1.2 The presence-sensing device should
device shall have a minimum object sensitivity have a minimum object sensitivity stated by the
such that an obstruction of a same or greater supplier. For example, an electro-optical device
size will always be detected anywhere within its may detect an opaque object with a diameter of
sensing field, regardless of the plane of 32 mm (1-¼ inch) anywhere in its sensing field,
intrusion. but allow an obstruction with a diameter of 25
mm (1 inch) to pass undetected at certain points
in the field.
8.3.1.3 The device shall not fail to change its E8.3.1.3 Muting may be accomplished by the
output state, if not muted, when it detects the device, its interface, auxiliary controls, or the
presence of an individual. machine control system. When the device
provides the muting, its output may or may not
change state.
8.3.1.4 Adjustment or configuration of presence- E8.3.1.4 Methods of meeting this requirement
sensing devices shall be capable of being include, but are not limited to, the use of key
supervised by the user. operated controls or controls located under
lockable covers.
Adjustments or configuration can include, but
are not limited to:
muting;
blanking;
power adjustments;
sensing field configuration;
reset functions.
8.3.1.5 The presence-sensing device shall E8.3.1.5 Indicators (usually red and green),
incorporate visual means to indicate that the displays or meters should be provided to
device is detecting an individual within the indicate the status of the device. The visual
effective sensing field of the device. means may be integral to the device or part of
the interface or machine control system.
Due to the prevalence of color blindness,
methods such as unambiguous positioning,
patterning, labeling or flashing of the indicators
may be effective in providing the indication
required.

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Extracts from ANSI B11.19-2003 8.3

Standards Requirements Explanatory Information
8.3.1.6 The presence-sensing device shall have
a maximum response time that shall not be
affected by object sensitivity or environmental
changes.
The safeguarding supplier shall provide the
maximum response time of the presence-
sensing device.
8.3.1.7 The RF (radio frequency) presence-
sensing device shall provide means to adjust
the sensitivity of the field. The field, once
adjusted, shall not decrease in sensitivity below
this established level.
8.3.1.8 The electro-optical device shall not be E8.3.1.8 When the electro-optical device is
affected by ambient light conditions or by exposed to signals from other electro-optical
changes in the device light source devices or to changes in ambient light
characteristics, such that an increase in commonly associated with windows, light
response time or object sensitivity occurs. fixtures, skylights, bay doors or work area lights,
the response time or object sensitivity should
not be adversely affected.
8.3.1.9 Components, subassemblies or modules
of electro-optical, RF, and area scanning
presence-sensing safeguarding devices shall be
designed and constructed to meet the
requirements of 6.1.
8.3.1.10 The area scanning device shall provide E8.3.1.10 These devices typically operate on
a means or operating mode to verify the size, the principle of “diffuse reflectance," which is a
shape, and detection capabilities of the principle of transmitting beam(s) of light to form
detection area or zone. a detection area or zone. When an object enters
the detection area, it reflects the transmitted
Information shall be provided by the area light back to the device, which then evaluates
scanning device supplier to identify the:
the object's position. The amount of reflected
a) maximum safeguarding range; light (degree of reflectance in percent) that can
b) minimum object sensitivity within the be reliably detected typically ranges from 1.8%
stated safeguarding range; to over 90% and can be represented graphically
c) maximum field of view in degrees; by reflectivity versus distance. For more
d) tolerance in the range measurement; and information, see IEC 61496, parts 1 and 3.
e) detection capabilities with respect to the
reflectivity of an object versus the distance
to the object.

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Extracts from ANSI B11.19-2003 8.3

Standards Requirements Explanatory Information
8.3.2 Installation, operation and maintenance
8.3.2.1 Exposure to the hazard(s) shall not be E8.3.2.1 The user should select a presence-
possible by reaching over, under or around the sensing device adequate to prevent individuals
sensing field of the device. Additional guards or from reaching over, under or around the sensing
safeguarding devices shall be provided to field during the hazardous portion of the
protect those areas. machine cycle. Additional safeguarding may be
required in conjunction with the device to meet
this requirement.
The effective sensing field shall be of adequate If individuals can place themselves between the
height, width, and depth so that entry of the sensing field and the hazard area, additional
individual into the hazard area is detected. safeguarding should be used in conjunction with
the device to prevent the individual from
exposure to the hazard.
When an individual can pass through the
sensing field, see the requirements of 8.3.2.3.
The electro-optical presence-sensing device
may fail to detect an individual's presence due
to reflective workpieces or objects in the vicinity
of the device. Care should be used to ensure
that these reflections do not render the device
ineffective.
Some examples of reflective objects include, but
are not limited to:
machine surfaces;
tooling;
work pieces;
hand tools;
auxiliary equipment;
workholding tables and fixtures.
Testing each set-up for minimum object
sensitivity should be done with an appropriate
test rod, following the supplier's
recommendation.
Where objects are placed within the defined
sensing field of an area optical laser scanner,
care should be taken to ensure that:
a) No shadows exist behind the objects such
that the device is rendered ineffective;
b) Removal of the object will not allow
undetected access to a hazard area.

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Extracts from ANSI B11.19-2003 8.3

Standards Requirements Explanatory Information
The device shall be installed such that it does Some installation hazards include, but are not
not create additional hazards. limited to:
pinch point hazards created by interference between
the device and moving members of the machine;
tripping hazards;
electrical shock hazards;
overhead or other "strike against" hazards;
thermal hazards.
Where such conditions can exist, additional
safeguarding may be required.
8.3.2.2 The presence-sensing device shall be E8.3.2.2 The safety distance calculation is
installed at a location so that the effective dependent upon the:
sensing field prevents individuals from reaching
total response time of the device as stated by the
the hazard(s) during the hazardous portion of safeguarding supplier;
the machine cycle.
response time of the interface;
response time of the control system;
time it takes the machine to stop hazardous motion;
and
depth penetration factor of the device.
See Annex D for the formula(e) to calculate the
safety distance.
Radio frequency devices have sensing fields
that can vary due to:
antenna(e) design;
effects of adjacent machinery and equipment;
field sensitivity adjustments; and
environmental factors (such as humidity or
temperature).
Before the machine is used for production
purposes, the RF device should be checked to
ensure that the effective field protects
individuals at the safety distance.
8.3.2.3 The presence-sensing device shall
protect individuals from hazards by initiating an
immediate stop command to the machine
control system when the sensing field of the
device is interrupted during the hazardous
portion of the machine cycle. It shall require re-
initiation of the normal actuating means prior to
the start or continuation of motion of the
machine.
When an individual can pass through the The operator should ensure that no individual is
sensing field of the presence-sensing device, in the safeguarded area before re-setting the
the device shall initiate an immediate stop device or machine control and initiating
command to the machine control system and hazardous motion.
shall require that the device or machine control
be manually reset before hazardous motion can
occur.

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Extracts from ANSI B11.19-2003 8.3

Standards Requirements Explanatory Information
8.3.2.3 (cont.) The reset device shall be Key lock reset switches located at various
located outside of the safeguarded area such positions around the safeguarded area may be
that it cannot be reached from within the one method of accomplishing this requirement.
safeguarded area. Reset of the device or
machine control shall not occur until verification
that the safeguarded area is clear of individuals.
8.3.2.4 Components, subassemblies or modules
of the interface or machine control system shall
meet the requirements of 6.1.
8.3.2.5 Muting of the device shall be permitted E8.3.2.5 Muting is typically accomplished by
during the non-hazardous portion of the interface circuits or auxiliary controls. The
machine cycle. Muting of the device shall be muting element should incorporate a similar
accomplished such that a single failure of a level of control reliability as the presence-
component, a subassembly or a module of the sensing device itself. A simple cam-operated
system / device that affects the performance of limit switch wired in parallel with the device's
the safety-related functions shall not prevent a output is inadequate, as its failure can remain
normal stop command from being initiated, or undetected.
shall cause an immediate stop command. In the
event of a failure, re-initiation of the machine
shall be prevented until the failure is corrected
or the system or device is manually reset.
In the presence of a failure, repetitive manual The intention of a manual reset is to encourage
reset of the system or device shall not be used the diagnosis of a failed component,
for production. subassembly, device or module. A second
failure may occur during the diagnostic or
troubleshooting process, negating the safety
function(s). Additional safeguarding should be
used to protect individuals during this process.
See the definition for control reliability and
Annex C for further information.
If the machine has reversing capability where a One method of meeting this requirement is by
muting hazard is possible, the control system the use of a control circuit interlock on the drive
shall include an automatic means so muting is motor starter (forward direction contact) to allow
only permitted in the forward direction. "muting" only in the forward direction when the
starter is energized. See 8.3.2.1
If an individual can pass through a sensing field
when the device is muted, means shall be
provided to ensure that the individual is outside
of the hazard area, or that the machine ceases
hazardous motion when the muting is removed.
8.3.2.6 Bypassing of the device shall be capable E8.3.2.6 Care should be taken to ensure that
of being supervised by the user. Indication that the operators and other individuals are aware
the device is active or bypassed shall be that the device has been bypassed so that
provided and shall be readily observable by individuals do not assume that the device is
individuals protected by the device. active and they are safeguarded when, in fact,
the device is bypassed.
When bypassed, the device, interface or control An amber indicator lamp or other means may be
system shall not indicate any state other than used to meet this requirement.
"bypass."

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Extracts from ANSI B11.19-2003 8.3

Standards Requirements Explanatory Information
When the device is bypassed, other When bypassed, the device's normal status
safeguarding must be provided and used. indicators can be misleading if still active. One
method that may be used to meet this
requirement is to remove power to the device or
to disable the normal status indicators when it is
bypassed or not being used.
Due to the prevalence of color blindness,
methods such as unambiguous positioning,
patterning, labeling or flashing of the indicators
may be effective in providing the indication
required.
8.3.2.7 The radio frequency device shall not be E8.3.2.7 The radio frequency device may be
adversely affected by changes around the affected by changes in the conditions around the
machine that may alter the sensitivity of the machine such as ambient conditions, the
device such that individuals are no longer placement of parts and tote boxes, grounding
detected in the sensing field at the proper safety conditions of the operator, or the movement of
distance. industrial trucks. These changes should not
adversely affect the performance of the device.
8.3.2.8 The total tolerance in the range E8.3.2.8 When the device is horizontally
measurement of an area scanning device shall mounted, the detection area or zone should be
be included in determining the distance from the visibly marked on the floor. This verification can
nearest recognized hazard to the detection area be accomplished by using a programming
or zone. This detection area shall be identified device or by physically identifying the perimeter
and tested to ensure that the device is able to of the detection area with an appropriate test
detect individuals entering the detection area. rod, following the supplier's recommendation.
The effective sensing field shall be verified for This verification is to ensure that a pre-
proper size and coverage upon installation, programmed device with a small or improper
replacement, or changes of the detection area. detection area is not used by mistake in an
installation requiring a larger field.
Area scanners may not be suitable (effective)
safeguards when used to protect an individual's
hands or fingers from hazards.
Items which can affect this suitability are:
response time;
minimum object sensitivity;
measurement accuracy.

Extracts from OSHA and ANSI A-17

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

A-18 Extracts from OSHA and ANSI

Appendix B. Specifications for User-built
Operator Stations
! DANGER
NON-WINTRISS OPERATOR STATION MAY NOT MEET SAFETY REQUIREMENTS
• Ensure that the Operator Station meets the requirements of all applicable safety regulations.
• Ensure that the Operator Station is wired correctly.
• Ensure that on any non-Wintriss Operator Station the Run buttons are placed so that two hands
are required to push them at the same time and that buttons cannot be pushed simultaneously
with one hand or with one hand and one elbow.
• Ensure that on any non-Wintriss Operator Station the Run buttons comply with the requirements
specified in Table B-2, page B-2.
• Ensure that on any non-Wintriss Operator Station the Run buttons have ring guards or other
means in place to prevent unintentional operation.
• Run all necessary tests to verify that each Operator Station is wired correctly and provides
proper anti-tie-down and anti-repeat protection. Test procedures are provided at the end of
chapters 2 and 3.
Failure to comply with these instructions will result in death or serious injury.

If you build your own Operator Station, be sure that it meets all the safety requirements in this
manual and in the applicable safety regulations. Minimum requirements are shown in
Table B-1.

Table B-1. Operator Station Requirements

Minimum Configuration Minimum Configuration
Single-Stroke Operation Only Single-Stroke and Continuous Operation
2 Palm buttons 2 Palm buttons
1 Emergency-stop button 1 Emergency-stop button
1 Prior Act button

Run Button Installation

Install the Run buttons on the Operator Station according to the following requirements:
• The Run buttons must be protected against unintended operation and placed so that the
concurrent use of both hands is required.
• A ring guard must be installed for each run button.
• If the buttons are in the same plane, they must be separated by a distance of at least 24 in.
(610 mm). If the Run buttons are not in the same plane, they may be placed closer together.
For examples of correctly designed operator stations, see the illustrations of Wintriss
operator stations, starting on page 2-19.

Specifications for User-built Operator Stations B-1

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

NOTICE
A Run-button timer is built into the WPC 2000. If the Run buttons on a standalone Operator
Station are not pressed within the 1/2-second “palm time” (“synchronous time” in ANSI
terminology) or the Run buttons on multiple Op. Stations are not pressed within the 5-second
“concurrent time,” the press will not cycle. See the description of the “Palm Time Lamp” on
page 1-8 and Switch 6 – Selecting Concurrent Time for More Than Two Operator Stations,
page 4-43.

Switch Requirements
Switches used for the Run, Emergency-stop, Top-stop and Prior Act buttons must meet the
specifications shown in Table B-2:
Table B-2. Specifications for Operator Station Switches
Switch Specifications
Run NEMA 12 or 13, UL rated
1-NC/1-N0 single contact block with transfer-style contacts. One contact bar
moves from N/C contacts to the N/O contacts to ensure that the N/C and N/O
contacts cannot be closed simultaneously.
(Allen Bradley AB-S 800T-D1JA, Square D 9001KR25GH13, or equivalent)
Must be guarded against accidental operation per ANSI and OSHA
requirements.
E Stop NEMA 12 or 13, UL rated
2-NC contacts, positive opening operation, “self-latching”
Top Stop NEMA 12 or 13, UL rated
2-NC contacts, positive opening operation
Prior Act NEMA 12 or 13, UL rated
1-NC with integral green pilot lamp for 24 Vdc operation. This lamp indicates
when the Prior Act timer is armed.
Must be guarded against accidental operation per ANSI and OSHA
requirements.

B-2 Specifications for User-built Operator Stations

Appendix C. 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 less than 1.26 for a 2-channel AutoSetPAC
or less than 1.22 for a 4-channel AutoSetPAC, 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-than-
normal 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 C-1 and
Figure C-2, page C-3, which show “PM items” and “PM tracking units.” If you do not find a
suitable PM item name, you can program in 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 162), 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.
“F##” WPC press control faults 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).

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Table C-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 C-2. PM Tracking Units

run hours1 days

weeks months
die changes ch. cycles (1 through 16)2
F## WPC press control faults (#: 45 - 59)3 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. Con-
tact DI 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 DI if you require
WPC.)
4 “Press overload” is only available with 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 the section, “Using the PM Monitor in Initialization mode.”

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 D.

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Once firmware has been upgraded, proceed to the section, “Using the PM Monitor in
Initialization mode.”

NOTICE
PM Monitor must be initialized before you can use it (see page C-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 “Program” 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
PRESS THE ENTER AUTO ADVANCE
KEY TO SELECT. CUSTOM SENSOR NAMES
SWITCH TO RUN WHEN SENSOR ENABLE MODE
DONE. PM MONITOR
SECURITY ACCESS

Figure C-1. “PM Monitor” Highlighted on SmartPAC 2 Initialization Menu

2. Select “PM Monitor” from the main Initialization menu (see Figure C-1). A screen will
appear asking for your password.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 C-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 C-5) where you can also change your password. Proceed to the section “Assigning
a new PM password number” to change your password (skip “Initializing the PM
Monitor” 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 this section to initialize the PM Monitor.

NOTICE
You should already have installed the firmware upgrade. If not, go back to the section, “Installing
the PM Monitor” before proceeding further.

Initializing the PM Monitor

1. Select “PM Monitor” from the main Initialization menu (see Figure C-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”.)

ENTER THE PASSWORD

provide this 5-digit number
0 to a DI tech person to obtain
USE THE KEYPAD TO ENTER NUMBERS. your PM password…
USE THE UP/DOWN CURSOR KEYS TO
INCREMENT/DECREMENT. PRESS ENTER
(Note: Your number may vary!)
WHEN DONE. PRESS RESET TO CANCEL.
65535

Figure C-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 ALERT EVERY

NEW ITEM

USE THE CURSOR KEYS TO MAKE

SELECTION. PRESS ENTER TO
SELECT, RESET WHEN DONE.

INIT F6

Figure C-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 at this screen. To change your password,
refer to the next section, “Assigning a New PM Password Number”.)

YOUR PRESS NAME PM MONITOR

select "Clear PM
info" to initialize the
CHANGE PASSWORD
CLEAR PM INFO PM monitor

USE THE CURSOR KEYS TO MAKE

SELECTIONS. PRESS ENTER TO ACCESS
THE SELECTION. PRESS THE RESET KEY
WHEN DONE.

Figure C-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 C-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
Chapter 4).
1. Go to the “PM Entry” screen (Figure C-4). Press F6 (Init).
2. You will see the “Initialize PM” screen (Figure C-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.

Select PM Item Names

You are now ready to set up PM parameters in Initialization. You can select a name for each
preventative 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 ALERT EVERY

NEW ITEM

USE THE CURSOR KEYS TO MAKE

SELECTION. PRESS ENTER TO
SELECT, RESET WHEN DONE.

INIT F6

Figure C-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.

PM MONITOR
YOUR PRESS NAME
"CUSTOM NAME"
AIR ROTARY SEALS
BCKSHFT BEARING 1
BCKSHFT BEARING 2
USE THE CURSOR KEYS TO
BCKSHFT BEARING 3
MAKE SELECTION. PRESS
BCKSHFT BEARING 4
ENTER TO SELECT, RESET BRAKE
WHEN DONE. BULL GEAR
CLUTCH VALVE
CONVEYOR 1
CONVEYOR 2
CONVEYOR 3
CONVEYOR 4
CONVEYOR 5
MORE CONVEYOR 6

Figure C-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.
5. As the screen suggests (see the next illustration), certain keys enable you to custom name
the item. The name you select can be any combination of alphanumeric characters,

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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 you
selection, press Reset. (For assistance in using the various keys, refer to Chapter 3 of
this manual.)

Figure C-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, 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 select the
DAYS
WEEKS tracking unit
MONTHS for the monitored
USE THE CURSOR KEYS TO
MAKE SELECTION. PRESS
STARTS/STOPS item
STROKES
ENTER TO SELECT, RESET DIE CHANGES
WHEN DONE. CH1 CYCLES
CH 2 CYCLES
CH 3 CYCLES
CH 4 CYCLES
CH 5 CYCLES
CH 6 CYCLES
CH 7 CYCLES
MORE CH 8 CYCLES

Figure C-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

to set frequency/tracking
units for monitored item,
ENTER A MAINTENANCE FREQUENCY FOR
AIR ROTARY SEALS use number keys (up
to 7-digit number), then
0 press Enter.
USE THE KEYPAD TO ENTER NUMBERS.
USE THE UP/DOWN CURSOR KEYS TO
INCREMENT/DECREMENT. PRESS ENTER
WHEN DONE. PRESS RESET TO CANCEL.

Figure C-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 item
is listed just below “new item”.:

YOUR PRESS NAME PM MONITOR

ITEM ALERT EVERY

NEW ITEM in this example, we
SLIDE ADJ. MOTOR 100 DIE CHANGES 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 C-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 mode.
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, set 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 “Program”. Press RESET to clear the error message. Then
load a tool number. Now set 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 SENSOR 1 This alert message

CHAIR BRACKET appears at the
SENSORS ENABLED PM ALERT main Run menu
when a PM alert
USE CURSOR KEYS TO DISABLE SENSORS condition is present.
MAKE SELECTIONS. COUNTERS Select PM Monitor
PRESS ENTER TO ACCESS BRAKE MONITOR
from this screen to
SELECTION. DIE PROTECTION
CAM SWITCH attend to the offending
PM MONITOR item.
LOAD NEW TOOL

Figure C-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 PM MONITOR

STATUS IS NORMAL notice that alert status
SLIDE ADJ. MOTOR is "normal"
ALERT AT 100 DIE CHANGES
CURRENT 75 DIE CHANGES
CLUTCH VALVE
ALERT AT 2000 STARTS/STOPS CLEAR
CURRENT 1001 STARTS/STOPS
F3
ALERT
GIBS
CHANGE F4
ALERT AT 1000000 STROKES
CURRENT VALUE
458239 STROKES
MORE
USE CURSOR KEYS TO CHANGE SELECTION
PRESS ENTER TO SELECT, RESET WHEN DONE

Figure C-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.

YOUR PRESS NAME PM MONITOR

shows how many alert
THERE IS 1 ITEM WITH ALERT STATUS alert conditions are
SLIDE ADJ. MOTOR !! ALERT!! current
CHECK AT 100 DIE CHANGES
CURRENT 101 DIE CHANGES
PM Monitor alerts
CLUTCH VALVE
you to check specific
CHECK AT 2000 STARTS/STOPS CLEAR item in "alert" status mode.
F3
CURRENT 1055 STARTS/STOPS ALERT Notice "!!ALERT!!"
GIBS CHANGE flashes.
CHECK AT 1000000 STROKES F4
VALUE
CURRENT 558836 STROKES
MORE
USE CURSOR KEYS TO CHANGE SELECTION
PRESS ENTER TO SELECT, RESET WHEN DONE

Figure C-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 C-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 D. 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 D-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 2-25, page 2-51). 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 D-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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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 D-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. In
Run mode, select COUNTERS, then enter the displayed counter values in the “COUNT”
column in Table D-1, below.

Table D-1. Record of Current Counts

Tool Number
Tool Name or Tool ID
COUNTER COUNT PRESET VALUE
Strokes You do not have to
record Preset Values.
Good Parts They are saved with the
tool settings.
Batch 1
Batch 2
Batch 3
Total Hits

2. 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.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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.

3. Power down your SmartPAC 2.

4. 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 D-1).

Figure D-1. Firmware Load Menu with “XFER FROM USB DISK” Highlighted

! 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.

5. Open the SmartPAC 2 enclosure or console.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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.

6. Locate the USB connector, J121, on the SmartPAC 2 board (refer to Figure 2-25,
page 2-51).

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.

7. 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.
8. Close the door of the enclosure or console.
9. Using the cursor keys, highlight “XFER FROM USB DISK,” as shown in Figure D-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 D-2.

Figure D-2. Firmware Load Menu with “LOAD NEW FIRMWARE” Highlighted

D-4 Updating SmartPAC 2 Firmware

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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.

10. With “LOAD NEW FIRMWARE” selected, as shown in Figure D-2, press ENTER. A
yellow status window appears with the message “YOU ARE ABOUT TO REPROGRAM
THE SMARTPAC 2 RTS UNIT. . .” (see Figure D-3).

Figure D-3. Firmware Load Menu with Yellow Status Window

11. Press ENTER to continue. A display like that shown in Figure D-4, page D-6 appears,
indicating that the firmware is being loaded. It takes about five minutes for the firmware
to load.

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Figure D-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 9-11
to install the firmware again.

12. 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.”
13. Power down the SmartPAC 2. Remove the USB disk from the USB connector.
14. 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.

15. 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 D-1, page D2 as follows:
a. Enter Run mode and select COUNTERS.
b. Enter the count values from Table D-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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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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.

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: Desktop
File name: SP2nnnnnnnn (where nnnnnnnn is your SmartPAC 2 serial number)
Save as type: 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 Self-
Extractor 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.

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.

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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 D-2.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 2-25, page 2-51). 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 2-25, page 2-51). 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 D-5, page D-10).

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Figure D-5. Firmware Load Menu with “RELOAD CURRENT FIRMWARE” Highlighted

4. Using the cursor keys, highlight “RELOAD CURRENT FIRMWARE,” as shown in

Figure D-5, and press ENTER. A yellow status window appears with the message “YOU
ARE ABOUT TO REPROGRAM THE SMARTPAC 2 RTS UNIT . . .” (see Figure D-6).

Figure D-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 D-7, page D-11, indicating that the firmware is being loaded. It takes
about five minutes for the firmware to load.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Figure D-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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D-12 Updating SmartPAC 2 Firmware

Appendix E. 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 E-7, page E-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 2-25, page 2-51 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 E-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 4-37,
page 4-57).
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 4-38, page 4-58) 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 E-1.

Table E-1. SmartPAC 2 Board: PS 2 and Y-Cable Configuration

Board Rev. # Identifier PS 2 Default Y–Cable
Configuration 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 Mouse Default Do not reverse
Connector
Rev. 6 & Higher Mouse = MS J120 N.A. N.A.
Keyboard = KB J125

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 2-25, page 2-51 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.” (If you wish, you can
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-left-
click 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 E-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 E-1).

Figure E-1. Internet Explorer Window with “Internet Options” Selected

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

3. On the Internet Options screen (see Figure E-2), click on the Security tab.

Figure E-2. Internet Options Screen

4. On the Security tab (see Figure E-3), click on the Custom Level button.

Figure E-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.

SmartView E-7
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 E-4) will display. Otherwise, you will be taken
directly to the SmartView Setup Page (see Figure E-5.

Figure E-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 E-5).

Figure E-5. SmartView Setup Page

3. Click in the Network Name window, and type “Demo1” as shown in Figure E-5.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

4. Click in the Press Name window, and type “Demo Press 1” as shown in Figure E-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 E-6 displays, asking if you want to download the
Mabry WinSock ActiveX control, click on the Install button.

Figure E-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 E-7), or contact your IT department for more information.

9. The SmartView Main Page (see Figure E-7, page E-10) should now appear. Click on the
Add to Favorites button to save this web site for future use.

SmartView E-9
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Figure E-7. SmartView Main Page

SmartView Operation
Setup Page
Follow these steps to fill in the information on the SmartView Setup Page (see Figure E-5,
page E-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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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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., ‘SPAC2-
12345678, 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 E-15 for instructions.

Main Page

The SmartView Main Page, shown in Figure E-8, page E-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.

SmartView E-11
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Figure E-8. SmartView Main Page with Status of Multiple Presses Shown

Press Status Information Page

The Press Status Information Page (see Figure E-9, page E-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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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Figure E-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 E-10,
page E-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.

SmartView E-13
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Figure E-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 E-11, page E-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.

E-14 SmartView
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Figure E-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 E-11).

SmartView E-15
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 E-12. Click on the Install button in the Security
Warning window to begin the download.

Figure E-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 E-13, displays.

Figure E-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.

E-16 SmartView
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 E-14 and Figure E-15.
Figure E-14 provides an example of a message indicating a successful Ping. Figure E-15
shows messages indicating two unsuccessful Ping attempts.

Figure E-14. Ping Utility Window with Example of a Successful Ping

Figure E-15. Ping Utility Window with Examples of Two Unsuccessful Pings

The “Host not found” message shown in Figure E-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.

SmartView E-17
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

If you continue to get results like those shown in Figure E-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.

E-18 SmartView
Appendix F. Upgrading from Original
SmartPAC to SmartPAC 2
NOTICE
ADDING PM MONITOR
If you had an AutoSetPAC module on your original SmartPAC, and the new SmartPAC 2 includes
Preventive Maintenance Monitor, you may need to upgrade your AutoSetPAC firmware. See
notice on page C-1.

NOTICE
USING ALPHANUMERIC TOOL NUMBERS IN SMARTPAC 2
If you convert from an original SmartPAC, the tool number mode in your SmartPAC 2 will default to
the Numeric mode. If you want to be able to use Alphanumeric mode in SmartPAC 2, you must
first do the following in SmartPAC 1:
1. Check to see that each tool has a valid, unique name. This name will become the tool number if
you switch to Alphanumeric mode.
2. If tools do not have names, enter Program mode and assign a unique name to each tool.
3. If two or more tools have been given the same name, reassign names so they are unique.

This appendix provides instructions in how to install a SmartPAC 2 in place of an original

SmartPAC. It shows you how to
• Back up tools on the original SmartPAC (next section)
• Mount the new SmartPAC 2 (page F-3)
• Swap wiring from the original SmartPAC to the SmartPAC 2 (page F-4)
• Restore tool settings to the SmartPAC 2 (page F-12)
• Enter initialization settings into SmartPAC 2 and perform system checkout (page F-14)

Backing Up Tools on Original SmartPAC

This section shows you how to back up tools on an original SmartPAC, using SBR
(SmartPAC Backup and Restore), which you can order from Wintriss.
SBR enables you to transfer backed-up tool settings from your original SmartPAC to your
new SmartPAC 2, using the hard drive of a connected computer or over a network. (For
instructions in how to restore settings, see Restoring Tools to SmartPAC 2, page F-12.)
SmartPAC Initialization settings cannot be restored to SmartPAC 2. Initialization settings
should be copied to a paper form (see the SmartPAC Initialization Setup Sheet at the back of
the manual), then, after tool settings have been restored, entered manually one-by-one into
SmartPAC 2, referring to the settings on the form.

SmartPAC to SmartPAC 2 Upgrade F-1

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

If you have programmed tool #99999999 in SmartPAC 1, be sure to make a copy of that tool
with a new tool number, then delete tool #99999999 before initiating a backup. In SmartPAC
2, tool #99999999 is reserved for Tool Template, a new SmartPAC feature (see page 5-5).
If your tool database is small and programming isn’t complicated, you may opt not to use a
backup utility. It may be simpler to record SmartPAC 1 tool settings on a setup sheet, then
enter the recorded settings into the SmartPAC 2.

Backing Up Tools to a Laptop

To use the SBR program to back up tools on your SmartPAC 1 to a connected laptop, refer to
the “Using SBR to Upgrade from SmartPAC 1 to SmartPAC 2” section of the SmartPAC
Backup and Restore Instruction Sheet, which is provided with the SBR software.

NOTICE
When setting up SmartPACs in SBR, make sure to identify the control you are backing up as a
“SmartPAC 1” and the control you are restoring to as a “SmartPAC 2.” With these settings, SBR
will back up all tools and Initialization settings from the SmartPAC 1, then, when it detects that a
SmartPAC 2 is connected, restore only the tool settings, ignoring the Initialization parameters.

Backing Up Tools to a Network Server

To back up tools on your SmartPAC 1 to a network server, perform the following steps:
1. With the Main Program Menu displayed on the SmartPAC 1 front panel, press the 1 and
CLEAR keys at the same time and hold them down for a few seconds until the Main
Initialization Menu displays.
2. Select the BACKUP/RESTORE menu item to display the Backup/Restore Control Menu
(see Figure F-1).

BACKUP/RESTORE CONTROL MENU

F1
F2
F3
DATE LAST BACKUP F4
PRESS A FUNCTION KEY
TO PERFORM THE DESIRED RESTORE F5
ACTIVTY. PRESS THE
RESET KEY TO EXIT.
BACKUP F6

Figure F-1. Backup/Restore Control Menu

F-2 SmartPAC to SmartPAC 2 Upgrade

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

3. Press the F6 (Backup) function key to begin the backup process. While the backup is
proceeding, the Status field on the SBR screen displays the message
Backing up...
When the backup is complete, the message in the Status field changes to
Connected
and the time at which the backup was completed displays in the Time of Last Backup field.

Removing SmartPAC 1 and Mounting SmartPAC 2

1. Make sure that SmartPAC 1 is powered down.
2. Label all wires connected to the SmartPAC 1 board, noting their pin locations, to facilitate
reconnecting them to SmartPAC 2. Also, make note of any ancillary wiring such as
warning beacons, relays, etc.

NOTICE
One convenient way to easily remember pinouts and wire colors is to snip wires about
1/2 in. from their connectors, leaving a colored wire stub in each pin location. You should
make sure you have enough wire before doing this.

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. Make a sketch showing how your wires and seal-tight cables enter your SmartPAC 1
enclosure.
4. Remove all wires and seal-tight from your SmartPAC 1.
5. Remove the DiProPAC and ProCamPAC boards from the SmartPAC 1 board if they are
installed and are to be reused.
6. Remove the SmartPAC 1 from your press and place it in a safe location.
7. Determine how you will mount your new SmartPAC 2.

NOTICE
The SmartPAC 2 enclosure is 1 in. taller than SmartPAC 1. For a panel mount, the
SmartPAC 2 cutout is the same size as for SmartPAC 1, but there must be at least a 1 in.
clearance from the bottom of the panel to the nearest switch plate. See see Table 1-1.
SmartPAC 2 with WPC 2000 Specifications, page 1-12.

SmartPAC to SmartPAC 2 Upgrade F-3

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

NOTICE
If the SmartPAC 1 you are replacing is integrated with a WPC II and you are using a
remote stroke select switch, you need a special 10-ft. wiring harness (P/N 4322701) to
connect the Stroke Select switch on the WPC to your SmartPAC 2.

8. Mount your new SmartPAC 2.

If you are installing a SmartPAC 2 enclosure, the two upper or two lower shock mounts
will have to be moved to accommodate the 1 in. increase in size. It may be a good idea to
replace all four shock mounts if they look worn. Some customization may be required if a
mounting bracket or pendant is used. In most cases, modifications are simple.

NOTICE
Be careful when mounting the SmartPAC 2 enclosure that the front door does not become
dislodged from its hinges.

Wiring the SmartPAC 2

NOTICE
If the SmartPAC 1 you are replacing is integrated with a WPC II and you are using a remote stroke
select switch, you need a special 10-ft. wiring harness (P/N 4322701) to connect the Stroke Select
switch on the WPC to your SmartPAC 2.

The wiring connections you need to make when you replace a SmartPAC with a SmartPAC 2
are shown in the tables starting on page F-6. These wiring tables cover the following
SmartPAC components:
• Main power
• Zero cam
• Input check, emergency stop, and top stop
• Resolver port
• Position sensor (if used)
• DiProPAC
• ProCamPAC
• WPC port (integration only)
• Remote dual op. station select (optional remote switch)
• WPC adjustment lockout switch (optional)
• Remote reset (optional)
• AutoSetPAC/WaveFormPAC 2- or 4-channel (optional)
• SFI (optional)
• MultiPAC (special port - optional)
Follow the instructions below to transfer the wiring from your old SmartPAC to SmartPAC 2.

F-4 SmartPAC to SmartPAC 2 Upgrade

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

1. Referring to the sketch you made in step 3 of the Removing SmartPAC 1 and Mounting
SmartPAC 2 procedure (page F-3), feed all wires into SmartPAC 2 knockout holes and
secure all seal-tight connectors. See AC Wiring on SmartPAC 2, page F-12 for details on
wiring the AC input and ground connections.
2. Check to make sure that the positions of jumpers JP101 (Master or Slave) and JP102 (high
or low speed) and input check switch (S101) are the same as they were in SmartPAC 1.
Refer to Figure 2-25, page 2-51 for jumper and switch locations.

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. Paying careful attention to orientation, reinstall and rewire the DiProPAC (connector J112
in Figure 2-25) and ProCamPAC (connector J111) boards you removed in step 5 of the
Removing SmartPAC 1 and Mounting SmartPAC 2 procedure (page F-3). Skip this step if
you purchased SmartPAC 2 with ProCamPAC and DiProPAC already installed.
4. Referring to the appropriate wiring table (Table F-1 through Table F-16) and to the wiring
diagram in Figure 1 at the back of the manual, terminate all wires at their appropriate pin
locations. Re-cut and strip wires where necessary.
5. Make the appropriate wiring connections between DiProPAC and ProCamPAC boards, if
installed (see step 3), and DSI 2 and the Cam Output assembly. See Figures 9, 10, and 11
at the back of the manual.
6. If you plan to network your SmartPAC 2, run Cat 5 cable with an RJ-45 connector into the
enclosure.

NOTICE
The Cat 5 cable can share seal-tight conduit with a low-voltage line or it can be run
separately. Do not run the Cat 5 cable with high-voltage wiring.

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. Check your work, making sure that all wiring is correct, terminal screws are tight and
making an electrical connection, and all connectors and socketed ICs are seated.
8. Connect AC input wires and ground wire to SmartPAC 2 as shown in AC Wiring on
SmartPAC 2, page F-12.

SmartPAC to SmartPAC 2 Upgrade F-5

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

9. When you are confident that all wiring is correct, apply power and wait about a minute for
SmartPAC 2 to boot up. Then Turn the Prog/Run key to PROG.

NOTICE
After SmartPAC 2 has booted up, you may see a message about the resolver position
being different. Press RESET to clear the message.

Table F-1. SmartPAC 1 to SmartPAC 2 Wiring Changes: Main Power

Original SmartPAC → SmartPAC 2
Signal Type Connector Pin Number Connector Pin Number Done (√)
L1 TB101 201 → AC Input 201
L1 - High
L2 TB101 202 → AC Input 202
L2 - Neutral
GND TB101 203 → GND Setscrew
terminal or
ground stud

Table F-2. SmartPAC 1 to SmartPAC 2 Wiring Changes: Zero Cam

Original SmartPAC → SmartPAC 2
Signal Type Connector Pin Number Connector Pin Number Done (√)

ZERO CAM TB101 211 → TB107 248

Table F-3. SmartPAC 1 to SmartPAC 2 Wiring Changes: Input Check, E-Stop, and Top Stop
Original SmartPAC → SmartPAC 2
Signal Type Connector Pin Number Connector Pin Number Done (√)

A (Input Chk.) TB101 205 → TB102 205

B (Input Chk.) TB101 206 → TB102 206
E-STOP TB101 207 → TB102 207
E-STOP TB101 208 → TB102 208
T-STOP TB101 209 → TB102 209
T-STOP TB101 210 → TB102 210

F-6 SmartPAC to SmartPAC 2 Upgrade

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Table F-4. SmartPAC 1 to SmartPAC 2 Wiring Changes: Resolver Port

Original SmartPAC → SmartPAC 2
Signal Type Connector Pin Number Connector Pin Number Done (√)

SHIELD TB106 212 → TB101 212

S1 TB106 213 → TB101 213
S2 TB106 214 → TB101 214
R1 TB106 215 → TB101 215
S3 TB106 216 → TB101 216
R2 TB106 217 → TB101 217
S4 TB106 218 → TB101 218

Table F-5. SmartPAC 1 to SmartPAC 2 Wiring Changes: Position Sensor (If Used)
Original SmartPAC → SmartPAC 2
Signal Type Connector Pin Number Connector Pin Number Done (√)

+V TB107 245 → TB107 245

POS TB107 246 → TB107 246
GND TB107 247 → TB107 247

Table F-6. SmartPAC 1 to SmartPAC 2 Wiring Changes: DiProPAC, 8-Channel

Original SmartPAC → SmartPAC 2
Signal Type Connector Pin Number Connector Pin Number Done (√)
SENSOR 1 TB501 282 → TB554 282
SENSOR 2 TB501 283 → TB554 283
SENSOR 3 TB501 284 → TB554 284
SENSOR 4 TB501 285 TB554 285
SENSOR 5 TB501 286 TB554 286
SENSOR 6 TB501 287 TB554 287
SENSOR 7 TB501 288 TB554 288
SENSOR 8 TB501 289 TB554 289
SEN. POWER TB501 290 TB554 290
GND TB501 291 TB554 291

SmartPAC to SmartPAC 2 Upgrade F-7

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Table F-7. SmartPAC 1 to SmartPAC 2 Wiring Changes: DiProPAC, 16-Channel

Original SmartPAC → SmartPAC 2
Signal Type Connector Pin Number Connector Pin Number Done (√)
SENSOR 1 TB551 282 → TB554 282
SENSOR 2 TB551 283 → TB554 283
SENSOR 3 TB551 284 → TB554 284
SENSOR 4 TB551 285 TB554 285
SENSOR 5 TB551 286 TB554 286
SENSOR 6 TB551 287 TB554 287
SENSOR 7 TB551 288 TB554 288
SENSOR 8 TB551 289 TB554 289
SENS. PWR. TB551 290 TB554 290
GND TB551 291 TB554 291
SENSOR 9 TB552 292 TB554 292
SENSOR 10 TB552 293 TB554 293
SENSOR 11 TB552 294 TB554 294
SENSOR 12 TB552 295 TB554 295
SENSOR 13 TB552 296 TB554 296
SENSOR 14 TB552 297 TB554 297
SENSOR 15 TB552 298 TB554 298
SENSOR 16 TB552 299 TB554 299
SENS. PWR. TB552 300 TB554 300
GND TB552 301 TB554 301

Table F-8. SmartPAC 1 to SmartPAC 2 Wiring Changes: ProCamPAC, 8-Channel

Original SmartPAC → SmartPAC 2
Signal Type Connector Pin Number Connector Pin Number Done (√)
CHANNEL 1 TB401 260 → TB401 260
CHANNEL 2 TB401 261 → TB401 261
CHANNEL 3 TB401 262 → TB401 262
CHANNEL 4 TB401 263 TB401 263
CHANNEL 5 TB401 264 TB401 264
CHANNEL 6 TB401 265 TB401 265
CHANNEL 7 TB401 266 TB401 266
CHANNEL 8 TB401 267 TB401 267
+ 5 VDC TB401 268 TB401 268
GND TB401 269 TB401 269
RELAY PWR. TB401 270 TB401 270

F-8 SmartPAC to SmartPAC 2 Upgrade

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Table F-9. SmartPAC 1 to SmartPAC 2 Wiring Changes: ProCamPAC, 16-Channel

Original SmartPAC → SmartPAC 2
Signal Type Connector Pin Number Connector Pin Number Done (√)
CHANNEL 1 TB451 260 → TB451 260
CHANNEL 2 TB451 261 → TB451 261
CHANNEL 3 TB451 262 → TB451 262
CHANNEL 4 TB451 263 TB451 263
CHANNEL 5 TB451 264 TB451 264
CHANNEL 6 TB451 265 TB451 265
CHANNEL 7 TB451 266 TB451 266
CHANNEL 8 TB451 267 TB451 267
+ 5 VDC TB451 268 TB451 268
GND TB451 269 TB451 269
RELAY PWR. TB451 270 TB451 270
CHANNEL 9 TB452 271 TB452 271
CHANNEL 10 TB452 272 TB452 272
CHANNEL 11 TB452 273 TB452 273
CHANNEL 12 TB452 274 TB452 274
CHANNEL 13 TB452 275 TB452 275
CHANNEL 14 TB452 276 TB452 276
CHANNEL 15 TB452 277 TB452 277
CHANNEL 16 TB452 278 TB452 278
+ 5 VDC TB452 279 TB452 279
GND TB452 280 TB452 280
RELAY PWR. TB452 281 TB452 281

Table F-10. SmartPAC 1 to SmartPAC 2 Wiring Changes: WPC Port (Integration Only)
Original SmartPAC → SmartPAC 2
Signal Type Connector Pin Number Connector Pin Number Done (√)

+RXD6 TB104 219 → TB105 327

-RXD6 TB104 220 → TB105 328
+TXD6 TB104 221 → TB105 329
-TXD6 TB104 222 → TB105 330
GND TB104 223 → TB105 326

SmartPAC to SmartPAC 2 Upgrade F-9

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Table F-11. SmartPAC 1 to SmartPAC 2 Wiring Changes: Remote Dual Op. Station Select
(Optional Remote Switch)
Original SmartPAC → SmartPAC 2
Signal Type Connector Pin Number Connector Pin Number Done (√)

OP STA 1 TB202 253 → TB107 254

OP STA 2 TB202 254 → TB107 253
GND TB202 256 → TB107 250

Table F-12. SmartPAC 1 to SmartPAC 2 Wiring Changes: WPC Adjustment Lockout Switch
(Optional)
Original SmartPAC → SmartPAC 2
Signal Type Connector Pin Number Connector Pin Number Done (√)

LOCKOUT TB202 255 → TB107 251

GND TB202 256 → TB107 250

Table F-13. SmartPAC 1 to SmartPAC 2 Wiring Changes: Remote Reset (Optional)

Original SmartPAC → SmartPAC 2
Signal Type Connector Pin Number Connector Pin Number Done (√)

REMOTE RES TB203 257 → TB107 249

GND TB203 258 → TB107 250

Table F-14. SmartPAC 1 to SmartPAC 2 Wiring Changes: AutoSetPAC/WaveFormPAC,

2 or 4 Channel (Integration Only)
Original SmartPAC → SmartPAC 2
Signal Type Connector Pin Number Connector Pin Number Done (√)

GND TB102 240 → TB103 240

+RXD2 TB102 241 → TB103 241
-RXD2 TB102 242 → TB103 242
+TXD2 TB102 243 → TB103 243
-TXD2 TB102 244 → TB103 244

F-10 SmartPAC to SmartPAC 2 Upgrade

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Table F-15. SmartPAC 1 to SmartPAC 2 Wiring Changes: SFI (Optional)

Original SmartPAC → SmartPAC 2
Signal Type Connector Pin Number Connector Pin Number Done (√)

+RXD1 TB102 235 → TB103 235

-RXD1 TB102 236 → TB103 236
TXD1 TB102 237 → TB103 237
+TXD1 TB102 238 → TB103 238
-TXD1 TB102 239 → TB103 239
GND TB102 240 → TB103 240

Table F-16. SmartPAC 1 to SmartPAC 2 Wiring Changes: MultiPAC (Special Port - Optional)
Original SmartPAC → SmartPAC 2
Signal Type Connector Pin Number Connector Pin Number Done (√)

+RXD3 TB103 224 → TB104 224

-RXD3 TB103 225 → TB104 225
TXD3 TB103 226 → TB104 226
+TXD3 TB103 227 → TB104 227
-TXD3 TB103 228 → TB104 228
GND TB103 229 → TB104 229

SmartPAC to SmartPAC 2 Upgrade F-11

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

AC Wiring on SmartPAC 2
Connect the AC input wires and ground wire as shown in Figure F-2.

AC Input Voltage: 115/230 V

Ground

NEUTRAL

LINE
L2 L1
(Neutral) (High)

Terminal block
Setscrew
terminal

Figure F-2. SmartPAC 2 AC Wiring (Inside Enclosure, Top Right)

Make your ground connection as follows:

• For SmartPAC 2 enclosure: Connect your ground (green or green/yellow) wire to the
set screw terminal on the inside of the enclosure, as shown in Figure F-2. Strip the
ground wire about 1/4 in. (6.4 mm) from the end, loosen the screw on the terminal, slide
the wire in the hole, and tighten the screw to secure the wire in place.
• For SmartPAC 2 panel mount: Connect the ground wire to the ground stud located on
the face plate below the AC input terminal block.

Restoring Tools to SmartPAC 2

You can use SBR to restore backed-up tools from a SmartPAC 1 to a SmartPAC 2 via a
connected laptop, or, if the SmartPAC 2 is on a network, you can restore tool settings from a
network server. However, you cannot restore SmartPAC 1 Initialization settings to
SmartPAC 2. To transfer this information to SmartPAC 2, you should copy Initialization
settings to a paper form before performing the back-up, then, after restoring the other setup
information, enter the Initialization settings from the form manually into SmartPAC 2 (see
System Checkout, page F-14).

F-12 SmartPAC to SmartPAC 2 Upgrade

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Restoring Tools from a Laptop

To use the SBR program to restore backed-up tools via a connected laptop, refer to the “Using
SBR to Upgrade from SmartPAC 1 to SmartPAC 2” section of the SmartPAC Backup and
Restore Instruction Sheet, which is provided with the SBR software.

NOTICE
Make sure to identify the control you are restoring to as a “SmartPAC 2.” When SBR detects that
a SmartPAC 2 is connected, it will restore only the backed-up tool settings, ignoring the
Initialization parameters.

Restoring Tools from a Network Server

To restore backed-up tools from a network server, perform the following steps:
1. On the Backup/Restore Control Menu in Initialization mode on the SmartPAC 2, press the
F5 (Restore) function key. The message shown in Figure F-3 displays.

F1
F2
F3
F4
F5
F6
F7
F8

Figure F-3. Backup/Restore Control Menu with Restore Confirmation Message Displayed

2. Press ENTER to continue with the restore. When the restore has been completed, the
following message displays on the Backup/Restore Control Menu:
Restore complete!

SmartPAC to SmartPAC 2 Upgrade F-13

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

System Checkout
To enter SmartPAC 1 initialization settings into SmartPAC 2 and test SmartPAC 2 operation,
do the following:
1. In SmartPAC 2, access the Main Initialization Menu.
2. Referring to the initialization information you recorded for the SmartPAC 1 control (see
Backing Up Tools on Original SmartPAC, page F-1), enter these initialization settings into
SmartPAC 2.
3. When you have finished entering initialization information, check to make sure that the
following parameters are set correctly, making changes if necessary:
• Position Sensor: Resolver Motion Mode should be set to Normal Motion unless you are
using a link motion press
• Position Sensor: Tool Number Mode should be set to Numeric Only
• Setup Network: If SmartPAC 2 is going to be networked, see page E-1 for detailed
instructions on how to enter network settings.
• Diagnostics: Set Clock is set to Clock at the factory. Make sure that the date and time
are correct. If they aren’t, make corrections.
4. Access the Main Program Menu, and select GO TO THE TOOL MANAGER.
5. When the Tool Manager screen displays, make sure that all tools that were programmed in
SmartPAC 1 are shown.

NOTICE
Tool Manager is a new screen that allows you to edit, load, delete, create, and copy tools.
See page 5-2 in this manual for instructions on how to program the Tool Manager.

NOTICE
Before loading a tool and setting up a new job, it is a good idea to create a test tool with a
tool number that is not currently being used. The test tool can be deleted when checkout
is complete.

6. Load a test tool, following the instructions in Creating a New Tool, page 5-3.
7. Turn the Program/Run key to RUN.
8. Go through the menu choices to make sure your new SmartPAC 2 is functioning properly.
Consult you manual for information on how to use new features that you are not familiar
with. You should also run the press without the tool in place. Make sure that all ancillary
equipment such as conveyors, feeds and cams are functioning properly.
9. Once you are satisfied that your SmartPAC 2 is operating identically to your SmartPAC 1,
you can load the tool for the next job, set up the die, and run the press.

F-14 SmartPAC to SmartPAC 2 Upgrade

Appendix G. 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 G-1, page G-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.

Replacing SmartPAC 2 PC Board G-1

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 G-1, page G-3), including connectors on the ProCamPAC and
DiProPAC boards (if installed).

NOTICE
Connectors are labeled “TBnnn” or “Jnnn” in Figure G-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 G-1).

5. With a ¼-in. nut driver, remove all six ¼-in. nuts and six of the eight ¼-in. standoffs (see
Figure G-1). Do not remove the upper right standoff for the ProCamPAC PC board or the
lower left standoff for the DiProPAC PC board.

G-2 Replacing SmartPAC 2 PC Board

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

ProCam DiPro Standoff (6 places) TB 102

(6 places)
U105

1/4” Nut
J113
Do not remove
this standoff

Battery Backed Up
JP 102

RAM Device
Low
High

Compact Flash U124

Input

Do not remove
this standoff
Check

SimpleTech

Serial # xxxxxxxx
Switch

Boot Loader
256MB
HWCF 256H
J114

S101

60-250
JP 101

TB 105
Master
INSERT

Slave

12-60
Lever
Ethernet
SOM (Industrial Computer)
USB
Mouse
USB TB 101 TB 107

PS
Do Not Remove
2 This Board

TB 106
PS 2
Mouse

PS
2 Keyboard (Rev. 6 & above) TB 104 TB 103

Insert Display Connector

this way

Figure G-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 G-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.

Replacing SmartPAC 2 PC Board G-3

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

10. Remove the Battery Backed Up Ram chip (U105 in Figure G-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 G-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 G-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 G-1) and the Master/Slave and
High/Low speed jumpers (J101 and J102 in Figure G-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 G-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 G-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.

G-4 Replacing SmartPAC 2 PC Board

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 G-2) will appear.

Figure G-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.

Replacing SmartPAC 2 PC Board G-5

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

G-6 Replacing SmartPAC 2 PC Board

Appendix H. 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.

Reporting Downtime and Scrap to SFC H-1

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 H-4).

Forced Idle Dialog Mode

If the SmartPAC 2 is set to Forced Idle Dialog mode (see Making Downtime Reporting
Settings, page H-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 H-1, page H-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 H-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 H-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 H-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 H-11, page H-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 H-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 H-2,
page H-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.

H-2 Reporting Downtime and Scrap to SFC

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 H-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 H-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 H-2).

Initial Updated
SmartPAC SFC SFC
Press Status/ Settings and Machine Machine
Operator Actions Displays State State

Press is running

Running time Running time

Press is stopped
by operator or
auxiliary equipment

Forced Dialog
time (5 min.)
(in min.)
Time

Forced Dialog
message displays
Idle time Downtime
Operator presses RESET Dialog Menu displays reason–
Backfill
Operator enters
downtime reason
with Backfill option

Operator enters Back on Line,

restarts press
Running time

Figure H-1. Forced Idle Dialog Mode Time Line (Downtime Reason Backfilled)

Reporting Downtime and Scrap to SFC H-3

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Initial Updated
SmartPAC SFC SFC
Press Status/ Settings and Machine Machine
Operator Actions Displays State State

Press is running

Running time Running time

Press is stopped
by operator or
auxiliary equipment

Forced Dialog
(in min.)

time (5 min.)
Time

Forced Dialog
message displays
Idle time Idle time
Operator presses RESET Dialog Menu displays

Operator enters
downtime reason
with Forward Fill option
Downtime
reason–
Forward fill

Operator enters Back on Line

Idle time
Operator restarts press
Running time

Figure H-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 H-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 H-2), applies it to the incompletely documented period. When the

H-4 Reporting Downtime and Scrap to SFC

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

downtime reason is backfilled (see Figure H-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”).

Initial Updated
SmartPAC SFC SFC
Press Status/ Settings and Machine Machine
Operator Actions Displays State State

Press is running

Running time Running time

Press is stopped
by SmartPAC SmartPAC
fault (1 sec.)
Error Dialog
(in min.)

time (5 min.)
Time

Forced Dialog
message displays
SmartPAC Downtime
Operator presses RESET Dialog Menu displays fault reason–
Backfill
Operator enters
downtime reason
with Backfill option

Operator enters Back on Line,

restarts press
Running time

Figure H-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 H-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

Reporting Downtime and Scrap to SFC H-5

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 H-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 H-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 H-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 H-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.

H-6 Reporting Downtime and Scrap to SFC

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 H-1, page H-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 H-4, page H-8) displays.

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Figure H-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 H-5) displays:

Figure H-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 H-1 explains each field on the Set Communications Menu and provides instructions
on how to make settings.

Table H-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 H-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 Downtime reasons are created in SmartPAC
32 CUSTOM 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 H-1. Set Communications Menu Settings (Cont.)

Field Settings
UNPLANNED RESET Specifies the number of strokes that must occur after the press
STROKES is restarted following a period of Unplanned Downtime,
Planned Downtime, or Changeover Time before SFC begins
PLANNED RESET
documenting the machine state as “Running Time.” This
STROKES
setting prevents additional press time from being attributed to
CHANGEOVER RESET a downtime reason when the operator forgets to select the
STROKES “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:
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 H-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 H-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 H-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 H-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 H-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 H-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 H-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 H-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 H-7, page H-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 H-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 H-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 H-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 H-8.

F1
F2
F3
F4
F5
F6
F7
F8

Figure H-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 H-7), the Dialog
Menu looks like the example shown in Figure H-9, page H-17. If “32 CUSTOM” is the
dialog screen mode setting, the Dialog Menu looks like the example shown in
Figure H-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 H-20).

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F1
F2
F3
F4
F5
F6
F7
F8

Figure H-9. Dialog Menu (“16/16” Dialog Screen Mode)

F1
F2
F3
F4
F5
F6
F7
F8

Figure H-10. Dialog Menu (“32 CUSTOM” Dialog Screen Mode)

2. Highlight the downtime reason you want (in Figure H-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 H-10).

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3. If Auto Backfill has been enabled on the Set Communications Menu (see Table H-1,
page H-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 H-11 displays.

F1
F2
F3
F4
F5
F6
F7
F8

Figure H-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 H-12), select the DIALOG MENU item.

F1
F2
F3
F4
F5
F6
F7
F8

Figure H-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 H-1,
page H-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 H-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 H-10, page H-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 3-12 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 H-1. page H-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 H-14, page H-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 H-13.
(To display the Security Access Menu, select SECURITY ACCESS from the Main
Initialization Menu–see Figure H-4, page H-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 H-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 4-8).

Making Scrap Entries

To document scrap for a currently running job, do the following:

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

1. With the tool loaded and running, select “COUNTERS” on the Main Run Menu (see
Figure H-12, page H-19) to display the Counters screen (see Figure H-14).

F1
F2
F3
F4
F5
F6
F7
F8

Figure H-14. Counters Screen with “Scrap Value” Function (F3) Shown

2. Press F3 (Scrap Value). The Scrap Value Entry window displays (see Figure H-15).

F1
F2
F3
F4
F5
F6
F7
F8

Figure H-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 H-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 H-16, page H-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 H-16).

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

F1
F2
F3
F4
F5
F6
F7
F8

Figure H-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 H-15,
page H-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 H-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 H-18,
page H-25).

F1
F2
F3
F4
F5
F6
F7
F8

Figure H-17. Counters Screen with Scrap Value Entry Window Displayed (10 Items Shown)

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

F1
F2
F3
F4
F5
F6
F7
F8

Figure H-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 H-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 H-19 displays.

Figure H-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.

H-26 Reporting Downtime and Scrap to SFC

Appendix I. 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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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 I-4).

Forced Idle Dialog Mode

If the SmartPAC 2 is set to Forced Idle Dialog mode (see Making Downtime Reporting
Settings, page I-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 I-1, page I-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 I-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 I-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 I-7).

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 I-10, page I-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 I-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 I-2,
page I-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 I-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 I-2).

Initial Updated
SmartPAC LETS LETS
Press Status/ Settings and Machine Machine
Operator Actions Displays State State

Press is running

Running time Running time

Press is stopped
by operator or
auxiliary equipment

Idle Dialog
time (5 min.)
(in min.)
Time

Forced Dialog
message displays
Idle time Downtime
Operator presses RESET Dialog Menu displays reason–
Backfill
Operator enters
downtime reason
with Backfill option

Operator enters Back on Line,

restarts press
Running time

Figure I-1. Forced Idle Dialog Mode Time Line (Downtime Reason Backfilled)

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Initial Updated
SmartPAC LETS LETS
Press Status/ Settings and Machine Machine
Operator Actions Displays State State

Press is running

Running time Running time

Press is stopped
by operator or
auxiliary equipment

Idle Dialog
(in min.)

time (5 min.)
Time

Forced Dialog
message displays
Idle time Idle time
Operator presses RESET Dialog Menu displays

Operator enters
downtime reason
with Forward Fill option
Downtime
reason–
Forward fill

Operator enters Back on Line

Idle time
Operator restarts press
Running time

Figure I-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 I-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 I-2), applies it to the incompletely documented period. When the
downtime reason is backfilled (see Figure I-3, page I-5 for a schematic time line), SmartPAC

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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”).

Initial Updated
SmartPAC LETS LETS
Press Status/ Settings and Machine Machine
Operator Actions Displays State State

Press is running

Running time Running time

Press is stopped
by SmartPAC SmartPAC
fault (1 sec.)
Error Dialog
(in min.)

time (5 min.)
Time

Forced Dialog
message displays
SmartPAC Downtime
Operator presses RESET Dialog Menu displays fault reason–
Backfill
Operator enters
downtime reason
with Backfill option

Operator enters Back on Line,

restarts press
Running time

Figure I-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 I-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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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 I-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 I-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 I-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 I-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 I-4) displays.

Figure I-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 I-5) displays:

Figure I-5. Set Communications Menu

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 I-1 explains each field on the Set Communications Menu and provides instructions
on how to make settings.

Table I-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 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 I-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 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 I-1. Set Communications Menu Settings (Cont.)

Field Settings
UNPLANNED RESET Specifies the number of strokes that must occur after the press
STROKES is restarted following a period of Unplanned Downtime,
Planned Downtime, or Changeover Time before LETS begins
PLANNED RESET
documenting the machine state as “Running Time.” This
STROKES
setting prevents additional press time from being attributed to
CHANGEOVER RESET a downtime reason when the operator forgets to select the
STROKES “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:
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 I-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 I-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 I-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 I-6. Dialog Fixed Name Choice Menu

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 I-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 I-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 I-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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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 I-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 I-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 I-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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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 I-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 I-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 I-8, page I-15.

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

F1
F2
F3
F4
F5
F6
F7
F8

Figure I-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 I-9) displays.

F1
F2
F3
F4
F5
F6
F7
F8

Figure I-9. Dialog Menu

2. Highlight the downtime reason you want (in Figure I-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 I-1,
page I-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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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 I-10 displays.

F1
F2
F3
F4
F5
F6
F7
F8

Figure I-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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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 I-11), select the DIALOG MENU item.

F1
F2
F3
F4
F5
F6
F7
F8

Figure I-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 I-1,
page I-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 I-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 3-12 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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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 I-13, page I-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 I-12.
(To display the Security Access Menu, select SECURITY ACCESS from the Main
Initialization Menu–see Figure I-4, page I-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 I-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 4-8).

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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 I-11, page I-17) to display the Counters screen (see Figure I-13).

F1
F2
F3
F4
F5
F6
F7
F8

Figure I-13. Counters Screen with “Scrap Value” Function (F3) Shown

2. Press F3 (Scrap Value). The Scrap Value Entry window displays (see Figure I-14).

F1
F2
F3
F4
F5
F6
F7
F8

Figure I-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 I-14 shows a scrap entry of “30” as an example.)

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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 I-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 I-15).

F1
F2
F3
F4
F5
F6
F7
F8

Figure I-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 I-14, page I-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 I-16, page I-22, in which “40” is used as the sample scrap
input.

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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

F1
F2
F3
F4
F5
F6
F7
F8

Figure I-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 I-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 I-17).

F1
F2
F3
F4
F5
F6
F7
F8

Figure I-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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SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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 I-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 I-18 displays.

Figure I-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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1128600 SmartPAC 2 with WPC 2000 Integration User Manual

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.

I-24 Reporting Downtime and Scrap to LETS

Appendix J. Option 1 User Inputs
This appendix shows you how to install, wire, program, monitor, and troubleshoot WPC 2000
Option 1. Option 1 is a “daughter” board you can install on your WPC 2000 Main Processor
board to increase the number of user inputs available for connection of auxiliary equipment to
WPC 2000. Option 1 is compatible with WPC 2000 systems running WPC 2000 version 1.70
and higher and, in the case of WPC 2000 Integrated units, SmartPAC 2 version 3.32 and
higher.
By providing connections for other press-related equipment, user inputs allow you to monitor
auxiliary press functions such as lubrication systems, conveyors, etc. and provide additional
press protection and operator safety. Up to 7 non-control-reliable inputs and up to 2 pairs of
control-reliable, cross-checked inputs are standard on WPC 2000 units. The Option 1 board
enables you to connect up to 20 additional non-control-reliable inputs and up to 4 additional
control-reliable, cross-checked input pairs to WPC 2000 (see Table J-1, page J-2).

! DANGER
USER INPUTS 1 THROUGH 7 AND 12 THROUGH 31 NOT SUITABLE FOR SAFETY USE
DO NOT use inputs 1 through 7 and 12 through 31 as part of any personnel protection system.
These inputs are not control reliable.
Failure to comply with these instructions will result in death or serious injury.

Option 1 user inputs, like WPC 2000 standard inputs, are programmed to stop the press
whenever connected equipment malfunctions. The type of stop (e.g., Top-stop, Emergency-
stop, etc.) is determined by the setting programmed for the specific input. Input stop types are
set to E-stop at the factory (see Table J-1) but can be changed at SmartPAC 2 (see Changing
User Input Stop Type, page J-8).
Non-control-reliable user inputs (i.e., inputs12-31) can be set to Top-stop, Top-stop/Lockout
(a new setting), E-stop, Estop/Lockout, or Unused. Control-reliable input pairs 32/33, 34/35,
36/37, and 38/39 can be set to E-stop or E-stop/Lockout. A setup sheet on which you can
document stop type assignments for Option 1 user inputs is provided on page J-12.
When any equipment connected via Option 1 user inputs to WPC 2000 issues a stop command
by opening a normally closed (N/C) input, WPC 2000 signals the press to perform the stop
type programmed for that input and displays the input’s fault code on the SmartPAC 2 display
(see Troubleshooting, page J-10 for a list of the fault codes assigned to Option 1 user inputs).
When a stop command is issued for any input programmed as E-stop/Lockout or Top-stop/
Lockout, the lockout relay also opens, causing the Lockout message to appear on the display.
The Lockout message must be cleared (by turning the Stroke Select switch to OFF, then to
INCH or one of the other operating modes) before the press can be restarted.
Ten of the non-control-reliable inputs have an input type of NPN, and ten are PNP (see
Table J-1). All of the control-reliable, cross-checked input pairs are PNP.

Option 1 User Inputs J-1

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Table J-1. Option 1 User Inputs: Input Type and Stop Type
User Input Number Input Type Default Stop Type *
User input 12 NPN E-stop
User input 13 NPN E-stop
User input 14 NPN E-stop
User input 15 NPN E-stop
User input 16 NPN E-stop
User input 17 NPN E-stop
User input 18 NPN E-stop
User input 19 NPN E-stop
User input 20 NPN E-stop
User input 21 NPN E-stop
User input 22 PNP E-stop
User input 23 PNP E-stop
User input 24 PNP E-stop
User input 25 PNP E-stop
User input 26 PNP E-stop
User input 27 PNP E-stop
User input 28 PNP E-stop
User input 29 PNP E-stop
User input 30 PNP E-stop
User input 31 PNP E-stop
User input 32 (cross-checked with input 33) PNP E-stop
User input 33 (cross-checked with input 32) PNP E-stop
User input 34 (cross-checked with input 35) PNP E-stop
User input 35 (cross-checked with input 34) PNP E-stop
User input 36 (cross-checked with input 37) PNP E-stop
User input 37 (cross-checked with input 36) PNP E-stop
User input 38 (cross-checked with input 39) PNP E-stop
User input 39 (cross-checked with input 38) PNP E-stop

* Option 1 user inputs are set to E-stop by default. Settings can be changed on the Press Control User Interlock
Menu (see page J-8). Option 1 inputs 12-31 can be programmed as E-stop, Top-stop, E-stop/Lockout,
Top-stop/Lockout, and Unused. Input pairs 32/33, 34/35, 36/37, and 38/39 can be set to E-stop or
E-stop/ Lockout.

J-2 Option 1 User Inputs

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Installing the Option 1 Board

To install the WPC 2000 Option 1 board (see Figure J-1, page J-4), perform the following
steps:

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 Option 1 board and remove it from its
anti-static bag.

NOTICE
Be sure to save the shipping box and protective anti-static bag in case you need to return
the Option 1 board.

2. Verify that the board has not been damaged during shipment. If damage has occurred,
contact Wintriss Tech. Support immediately.

! 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.

3. Shut off power to WPC 2000.

4. Open the WPC 2000 enclosure or console.
5. Locate the four 1/4-in. hex standoffs in the lower left corner of the WPC 2000 Main
Processor board.

NOTICE
If there are six 1/4-in. standoffs in the area where the Option 1 board is to be installed,
remove the top middle and bottom middle standoffs, using a 1/4-in. nut driver. Be sure to
remove the screws underneath the standoffs so they don’t short out the board.

Option 1 User Inputs J-3

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

DSV/Lockout
Relay board
Auxiliary E-Stop
Relay board
(Optional)

WPC 2000 Main

Processor board

Standoffs and
Phillips screws
(4 places)
WPC 2000
Option 1 board

438 439 440 441 442 443 444 445 446 447

431 432 433 434 435 436 437

Green
448 449 450 451 452 453 454 Orange
455 456 457 458 459 460 461 462 463 464

Figure J-1. Option 1 Board Installed on WPC 2000 Main Processor Board

6. Making sure you are grounded, align the holes in the four corners of the Option 1 board
with the four standoffs on the WPC 2000 Main Processor board (refer to Figure J-1 for
correct placement of board), and slowly push the board down until both connectors are
seated. Then screw the board down, using the Phillips screws provided.
7. If you are ready to connect auxiliary equipment to the Option 1 board, proceed to the next
section. Otherwise, close the door of the WPC 2000 enclosure or console.

J-4 Option 1 User Inputs

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Wiring Option 1 User Inputs

Wiring connections for WPC 2000 Option 1 user inputs are made on terminal blocks TB601
and TB602 on the Option 1 board (see Figure J-2). Pin numbers are shown in Table J-2 and
Table J-3, page J-6, and in Figure 25 at the end of the manual.

+5V
B processor +5V
LED A processor
DS629 LED
DS630

TB601 user input wiring connectors TB602 user input wiring connectors

Group 8 LEDs Group 9 LEDs Group 10 LEDs Group 11 LEDs

10
1
1

438 439 440 441 442 443 444 445 446 447
TB601

TB602

431 432 433 434 435 436 437

20
11
14
8

448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464

Figure J-2. WPC 2000 Option 1 Board

Wire from the terminal shown in Table J-2 or Table J-3 to your equipment and then back to
either +24 Vdc or ground. If you remove any of the jumpers installed at the factory, make
sure to bypass those inputs by connecting them to +24 Vdc or ground, as shown in Table J-2
or Table J-3. TB601 provides one +24 Vdc terminal and one ground terminal for jumper
connections. TB602 provides two +24 Vdc terminals and two ground terminals.

Option 1 User Inputs J-5

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Table J-2. WPC 2000 Option 1 Board: Wiring Connections, TB601

Terminal for Jumper
Pin # User Input Bypass Connection
Upper Row
431 User input 32 + (cross-checked with user input 33) +24 Vdc
432 User input 34 + (cross-checked with user input 35) +24 Vdc
433 User input 12 - Ground
434 User input 13 - Ground
435 User input 14 - Ground
436 User input 15 - Ground
437 +24 Vdc
Lower Row
448 User input 22 + +24 Vdc
449 User input 23 + +24 Vdc
450 User input 24 + +24 Vdc
451 User input 25 + +24 Vdc
452 User input 36 + (cross-checked with user input 37) +24 Vdc
453 User input 38 + (cross-checked with user input 39) +24 Vdc
454 Ground

Table J-3. WPC 2000 Option 1 Board: Wiring Connections, TB602

Terminal for Jumper
Pin # User Input Bypass Connection
Upper Row
438 User input 33 + (cross-checked with user input 32) +24 Vdc
439 User input 35 + (cross-checked with user input 34) +24 Vdc
440 User input 16 - Ground
441 User input 17 - Ground
442 User input 18 - Ground
443 User input 19 - Ground
444 User input 20 - Ground
445 User input 21 - Ground
446 +24 Vdc
447 +24 Vdc
Lower Row
455 User input 26 + +24 Vdc
456 User input 27 + +24 Vdc
457 User input 28 + +24 Vdc
458 User input 29 + +24 Vdc
459 User input 30 + +24 Vdc

J-6 Option 1 User Inputs

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Table J-3. WPC 2000 Option 1 Board: Wiring Connections, TB602 (Cont.)
Terminal for Jumper
Pin # User Input Bypass Connection
460 User input 31 + +24 Vdc
461 User input 37 + (cross-checked with user input 36) +24 Vdc
462 User input 39 + (cross-checked with user input 38) +24 Vdc
463 Ground
464 Ground

When you have finished wiring user inputs, verify that your connections are good by checking
the LEDs for the appropriate pin numbers (see Figure J-3, below). You can also verify that

Shaded LEDs are green; all others are red. LEDs in each group are identified by number.
Corresponding pin numbers for each LED are also shown.

+ 5 VDC A + 5 VDC B

455 - User input 26 +

456 - User input 27 +
448 - User input 22 + 457 - User input 28 +
449 - User input 23 + 458 - User input 29 +
450 - User input 24 + 459 - User input 30 +
451 - User input 25 + 460 - User input 31 +
452 - User input 36 + (x-ch. w/37) 461 - User input 37+ (x-ch. w/36)
453 - User input 38 + (x-ch. w/39) 462 - User input 39 + (x-ch. w/38)

1 2 3 4 5 6 1 2 3 4 5 6 7 8

GROUP 8 GROUP 10

438 - User input 33 + (x-ch. w/32)

439 - User input 35 + (x-ch. w/34)
431 - User input 32 + (x-ch. w/33) 440 - User input 16 -
432 - User input 34 + (x-ch. w/35) 441 - User input 17 -
433 - User input 12 - 442 - User input 18 -
434 - User input 13 - 443 - User input 19 -
435 - User input 14 - 444 - User input 20 -
436 - User input 15 - 445 - User input 21 -

1 2 3 4 5 6 1 2 3 4 5 6 7 8

GROUP 9 GROUP 11

Serial port Receive and Transmit LEDs on Main Processor board (visible through holes in Option 1 board)

Figure J-3. WPC 2000 Option 1 Board: LED Map

Option 1 User Inputs J-7

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

the inputs are connected properly by displaying the appropriate input status screen (see
Viewing the Status of User Inputs, page J-9).

Changing User Input Stop Type

WPC 2000 Option 1 user inputs are set to E-stop at the factory (see Table J-1, page J-2) but
can be modified on the Press Control User Interlock Menu in SmartPAC 2 Initialization. User
inputs 12-31 can be set to Top-stop, Top-stop/Lockout (a new setting), E-stop, E-stop/
Lockout, or Unused. Cross-checked input pairs 32/33, 34/35, 36/37, and 38/39 can be set to
E-stop or E-stop/Lockout.
Top-stop/Lockout is also available as an option for WPC 2000 user inputs 1-7 if you have
SmartPAC 2 firmware version 3.32 or higher. The Unused setting can be selected to bypass
inputs you are not connecting.

NOTICE
You cannot program control-reliable, cross-checked inputs 32-39 (or inputs 8-11 in WPC 2000) as
Top-stop/Lockout or Unused. These safety inputs must be set as either E-stop or E-stop/Lockout.

You can assign names to the auxiliary equipment you are connecting to Option 1 inputs on the
same screen on which you set the input stop type. A setup sheet on which you can document
equipment name/user input assignments is provided on page J-12.
To change the stop type for a user input, follow these instructions:
1. On the SmartPAC 2 Main Initialization Menu (see Figure 4-1, page 4-1), move the
highlight bar to PRESS CONTROL, using the cursor keys, and press ENTER. The WPC
Initialization Menu (see Figure 4-18, page 4-23) displays with the USER INTERLOCKS
item highlighted by default.
2. On the WPC Initialization Menu, press ENTER with USER INTERLOCKS highlighted.
The Change User Interlocks screen (see Figure J-4, page J-9) displays.
3. Press the function key (i.e., F2, F3, or F4) corresponding to the group of user inputs (i.e.,
Group 1, Group 2, or Group 3) within which the user input you wish to update falls. The
Press Control User Interlock Menu for that user input group displays (see Figure 4-19,
page 4-24, which uses the screen for standard user inputs 1-11 as an example) with the
stop type for the first user input in the group highlighted.
4. Perform steps 2 through 4 of the procedure documented in User Interlocks, page 4-24 to
change the stop type and assign a name to each user input you wish to re-program.
5. When you are finished, press RESET to save your settings.

J-8 Option 1 User Inputs

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Figure J-4. Change User Interlock Screen

Viewing the Status of User Inputs

You can view the status of WPC 2000 Option 1 user inputs just as you can view the status of
the standard user inputs 1-11. Viewing input status is a useful diagnostic tool for
troubleshooting your Option 1 user inputs and the auxiliary equipment they are connected to.
To view input status, follow these steps:
1. On the WPC Initialization Menu (see Figure 4-18, page 4-23), move the selection bar to
INPUT STATUS, using the cursor keys, and press ENTER. The Display WPC Input Status
screen, shown in Figure J-5, displays.

Figure J-5. Display WPC Input Status Screen

Option 1 User Inputs J-9

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

2. Press the function key (i.e., F4, F5, or F6) corresponding to the group of user inputs (i.e.,
Group 1, Group 2, or Group 3) within which the user input whose status you want to view
falls. The WPC Interlock Input Status screen for that user input group displays (see
Figure 4-28, page 4-46, which uses the Group 1 screen as an example).
The status of all user inputs (OFF or ON) is shown in the STATUS column. Inputs that are
ON are highlighted. OFF inputs are not highlighted. In addition, an OFF input may
generate the fault code specific to that input on the SmartPAC 2 display. “Unused” inputs
show an OFF status but do not generate a fault code display.

Troubleshooting
Table J-4 shows the fault code associated with each Option 1 user input that appears on your
SmartPAC 2 display when there is a problem with the auxiliary equipment that input is
connected to. An additional fault code is documented following the table.
To correct the problem that caused the fault code to display, check the equipment and wiring
connected to that user input. When you have corrected the problem, reset SmartPAC 2 and
WPC 2000. If the problem recurs, contact Wintriss Tech. Support.

Table J-4. WPC 2000 Option 1 Fault Codes

Terminal for
Fault Code User Input Stop Type Pin # Jumper Connection
120 User 12 Top-stop 433 Ground
121 User 13 Top-stop 434 Ground
122 User 14 Top-stop 435 Ground
123 User 15 Top-stop 436 Ground
124 User 16 Top-stop 440 Ground
125 User 17 E-stop 441 Ground
126 User 18 E-stop 442 Ground
127 User 19 E-stop 443 Ground
128 User 20 E-stop 444 Ground
129 User 21 E-stop/Lockout 445 Ground
130 User 22 Top-stop 448 +24 Vdc
131 User 23 Top-stop 449 +24 Vdc
132 User 24 Top-stop 450 +24 Vdc
133 User 25 Top-stop 451 +24 Vdc
134 User 26 Top-stop 455 +24 Vdc
135 User 27 E-stop 456 +24 Vdc
136 User 28 E-stop 457 +24 Vdc
137 User 29 E-stop 458 +24 Vdc
138 User 30 E-stop/Lockout 459 +24 Vdc
139 User 31 E-stop 460 +24 Vdc

J-10 Option 1 User Inputs

SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Table J-4. WPC 2000 Option 1 Fault Codes (Cont.)

Terminal for
Fault Code User Input Stop Type Pin # Jumper Connection
User 32 paired E-stop 431 +24 Vdc
140, 144
with User 33 E-stop 438 +24 Vdc
User 34 paired E-stop 432 +24 Vdc
141, 145
with User 35 E-stop 439 +24 Vdc
User 36 paired E-stop/Lockout 452 +24 Vdc
142, 146
with User 37 E-stop/Lockout 461 +24 Vdc
User 38 paired E-stop/Lockout 453 +24 Vdc
143, 147
with User 39 E-stop/Lockout 462 +24 Vdc

F148 Fault
Problem: If the message “F148 OPTION BOARD NOT CORRECT” appears on your
SmartPAC 2 display, it means either that the Option 1 board is not seated properly
in the WPC 2000 board or has been removed from the WPC 2000 board.

Remedy: Make sure that the Option 1 board is seated firmly and that the screws securing it
to the WPC 2000 board are tight. If the Option 1 board has been removed,
re-initialize WPC 2000 and cycle power to the SmartPAC 2 control.

NOTICE
Removal of the Option 1 board should only be performed after careful consideration of safety
implications. If you have wired and programmed cross-checked user inputs on the Option 1 board,
removal of the board could render press operation hazardous.

NOTICE
When you re-initialize WPC 2000, all press control parameters (e.g., option switch settings, brake
monitor settings, etc.) are reset to their default values. To avoid losing data you have painstakingly
entered, copy existing press control parameters to a table so you can replace them when WPC
2000 is re-initialized.

To re-initialize WPC 2000, put the SmartPAC 2 into Initialization mode, then select, in
succession, “PRESS CONTROL” on the Main Initialization Menu, “PRESS
PARAMETERS” on the WPC Initialization Menu, and, finally, “INITIALIZE
PARAMETERS” on the Press Control Parameter Menu.

Option 1 User Inputs J-11

1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Option 1 User Input Setup Sheet

Terminal
Fault for Jumper Name of Auxiliary
User Input Code Stop Type * Pin # Connection Equipment
User 12 120 433 Ground
User 13 121 434 Ground
User 14 122 435 Ground
User 15 123 436 Ground
User 16 124 440 Ground
User 17 125 441 Ground
User 18 126 442 Ground
User 19 127 443 Ground
User 20 128 444 Ground
User 21 129 445 Ground
User 22 130 448 +24 Vdc
User 23 131 449 +24 Vdc
User 24 132 450 +24 Vdc
User 25 133 451 +24 Vdc
User 26 134 455 +24 Vdc
User 27 135 456 +24 Vdc
User 28 136 457 +24 Vdc
User 29 137 458 +24 Vdc
User 30 138 459 +24 Vdc
User 31 139 460 +24 Vdc
User 32 paired 431 +24 Vdc
140, 144
with User 33 438 +24 Vdc
User 34 paired 432 +24 Vdc
141, 145
with User 35 439 +24 Vdc
User 36 paired 452 +24 Vdc
142, 146
with User 37 461 +24 Vdc
User 38 paired 453 +24 Vdc
143, 147
with User 39 462 +24 Vdc

* Option 1 user inputs are set to E-stop by default. Settings can be changed on the Press Control User Interlock Menu
(see page J-8). Option 1 inputs 12-31 can be programmed as E-stop, Top-stop, E-stop/Lockout, Top-stop/Lock-
out, and Unused. Input pairs 32/33, 34/35, 36/37, and 38/39 can be set to E-stop or E-stop/ Lockout.

J-12 Option 1 User Inputs

Glossary
NOTICE
Cross-references to other glossary entries are shown in italics.

ACTS See Auto-compensated Top Stop.

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 advance A ProCamPAC feature that allows cam channels to be

programmed for speed-sensitive functions (e.g., feed advance,
pilot release, etc.) on variable speed presses. A channel
programmed as Auto Advance automatically advances cam
timing as the speed of the press increases and delays timing as
speed decreases. The rate of advance or delay is controlled by an
advance constant, a specified number of degrees of advance for
each 100 SPM increase in press speed.

auto carry-up A signal that causes the press to automatically complete the
stroke, stopping at TDC, when the operator releases his hands
from the palm buttons after the Auto Carry-up Angle has been
reached. Also called “Operator Station mute.”

auto carry-up angle The crank angle at which the pinch point has closed to less than
1/4 in. (6 mm), an opening determined by OSHA to be too small
to pose a hazard to the operator.

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.

Auto-compensated Top A WPC 2000 feature, designed specifically for variable-speed

Stop (ACTS) presses, that adjusts the top-stop angle automatically as press
speed changes or the brake wears.

Glossary GL-1
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Automatic Continuous A WPC 2000 feature that allows an external device like a feeder
On-demand or robot to signal WPC 2000 to start the press in Continuous
mode and maintain operation in Continuous.

Automatic Single-stroke A WPC 2000 feature that allows an external device like a feeder
or robot to signal WPC 2000 to stroke the press when a feed has
been completed.

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.

BDC Abbreviation for bottom dead center.

brake monitor A SmartPAC 2/WPC 2000 feature that checks for brake wear.
calculated safety distance See safety distance.

cam channels Relays that open and close on signals from the programmable
cam switch to turn auxiliary equipment on and off at specified
crankshaft angles.

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.,

WPC, SFI, etc.) or received from an installed option.

concurrent time The length of time within which each pair of palm switches on all
Operator Stations connected to WPC 2000 must be pressed in
order to start the press. This interval is 5 seconds. If the
concurrent time is exceeded by any Operator Station, the press
will not start.

control component failure Another name for control reliability.

control reliability A regulation defined in ANSI B11.1-2009 and OSHA 1910.217

requiring that a single component failure in a clutch/brake control
circuit not prevent the normal stopping action of the press, not
create an unintended stroke, and not allow initiation of a
subsequent stroke until the failure has been corrected.
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.

GL-2 Glossary
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

crank angle clock A graphical indicator on the SmartPAC 2 display that shows the
angle of rotation of the press’s crankshaft.

critical angle The point in the crankshaft rotation after which a stop signal to
the press cannot prevent the die from closing.

depth penetration factor A value used in the ANSI formula for calculating the safety
distance. The depth penetration factor is a measure of how far an
object, like an operator’s hand, can move through the light
curtain before the light curtain reacts.

diode A component that reduces or eliminates electrical noise.

dual diverse redundancy A WPC 2000 feature in which both microprocessor systems
belong to different architectures, are programmed using different
programming languages, function independently of one other,
have separate power supplies, and provide different information
to the operator. Dual diverse redundancy provides optimum
clutch/brake control and operator safety.

Dual Safety Valve The control-reliable device on the press that controls the flow of
air to the press’s clutch.

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.

fault (error) messages Messages appearing on the SmartPAC 2 LCD that indicate a fault
condition.

hand-speed constant A value used in the ANSI formula for calculating the safety
distance. The hand-speed constant is the distance one can
theoretically move one’s hand and arm in one second. OSHA
recommends a hand-speed constant of 63 inches-per-second.

interrupted stroke A condition that occurs when the press has been Emergency-
stopped before the completion of the stroke by either the operator
or an automatic device for personnel or equipment protection.
During an interrupted stroke condition, the message “Interrupted
Stroke” flashes in the status box at the top of the SmartPAC 2
screen.

Glossary GL-3
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

lockout A WPC 2000 function that prevents the press from being
restarted after clearing of fault messages that indicate serious
errors. The lockout condition is indicated by the lockout
message, which appears on the SmartPAC 2 display. Lockout
provides an added safety feature to the WPC 2000.

lockout message A message (i.e., “PRESS CONTROL IS IN LOCKOUT

MODE”) that appears on the SmartPAC 2 display indicating that
a serious error condition has occurred.

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.

Micro-inch A WPC 2000 feature that allows the operator to set the amount of
time in milliseconds that the Dual Safety Valve is open and,
therefore, the distance the ram will travel when the Run/Inch
switches on the Operator Station are pushed in Inch mode.
Micro-inch is designed for high-speed and/or short-stroke
presses.

NEMA 12 A rating that certifies that an electrical device is protected against

dust, water, and oil.

ninety degree (90)° stop- A test required to set the proper safety distance for personnel-
time test guarding devices, including light curtains, two-hand controls, and
type-B movable barriers. This test checks the stopping time of
the press at its most critical stopping point, normally the midpoint
of the downstroke (i.e., 90°), while the press is running in
Continuous mode (or Single-stroke if the press does not have a
selector setting for Continuous). Stopping time is a value
required in the ANSI formula for calculating the safety distance.

object sensitivity A value required in deriving the depth penetration factor for a
light curtain. Object sensitivity specifies the smallest diameter
object that a light curtain can detect anywhere in its field.

on-off setting Stroke angle settings at which the cam channel is to turn “on”
(activate) and turn “off” (deactivate).

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.

GL-4 Glossary
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

overrun limit switch A device mounted on the press to check the accuracy of the
crankshaft angle maintained by the resolver. The overrun limit
switch consists of a magnet, which is mounted on the crankshaft
(or other shaft), and a stationary magnetic switch, which is
mounted just above the magnet so that it detects the magnetic
field on every stroke. The magnetic switch is also called an
“overrun sensor.”
WPC 2000 checks the resolver crankshaft angle by comparing it
to the signal received from the overrun limit switch. When the
signal is not received at the same resolver angle on every stroke,
WPC 2000 knows that the resolver is no longer rotating at a 1:1
ratio with the press.

overrun timing A WPC 2000 feature that provides a backup for top-stop timing,
stopping the press if the top-stop output relay should fail.
Overrun timing is a function of the stopping time of the press and
is influenced by the condition of the brake linings and press
speed. It is also dependent on proper installation of the overrun
limit switch.

palm time The length of time within which the two palm switches on each
Operator Station connected to WPC 2000 must be activated in
order to start the press. This interval is 1/2 (0.5) second as
required by ANSI. If the palm time on any Operator Station is
exceeded, the press will not start. ANSI standards refer to the
palm time as synchronous time.
pinch point The hazardous area between the upper and lower die from which
OSHA mandates that the operator should be protected by
installation of safety equipment such as light curtains, two-hand
controls, and other barriers.

PMA Stands for Precision Metalforming Association.

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.

resolver An electrical component mounted on the press used by

SmartPAC 2/WPC 2000 to provide continuous information about
the position of the crankshaft and to maintain a count of the
number of revolutions it makes. The resolver, which has internal
windings and works on the principle of inductance, turns at a
one-to-one ratio (1:1) with the crankshaft.

Glossary GL-5
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

response time The length of time it takes SmartPAC 2 to activate the machine’s
brake.

safety distance The distance from the pinch point that OSHA requires safety
equipment such as light curtains, two-hand controls, and type-B
movable barriers to be mounted to assure the safety of the
operator. The safety distance is calculated using a precise
formula set by OSHA regulations and/or ANSI standards. The
formula uses the results of the ninety degree (90°) stop-time test.

security access Settings made in Initialization that control the amount of access
SmartPAC 2 users are given to SmartPAC 2 functions.

slow RPM A setting used with the auto advance feature that indicates the
slowest speed at which the press will be operated.

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.

start time The amount of time it takes the resolver to start turning after the
Dual Safety Valve (DSV) is energized.

stopping angle The number of degrees of crankshaft rotation required for the
press to stop after a “stop” command is issued. The stopping
angle is calculated by subtracting the crankshaft position when
the dual safety valve (DSV) is closed from the press’s position
when it actually stops. The stopping angle is useful in
determining where to set Top Stop and in die-protection settings.

stopping time The length of time it takes the crankshaft to stop moving after the
Dual Safety Valve (DSV) deactivates.

strokes counter A SmartPAC 2 feature that maintains a count of the number of

strokes made by the press. The strokes counter is incremented
once for each cycle of the press.

suppressor A component that reduces or eliminates electrical noise.

synchronous time The ANSI term for palm time.

TDC Abbreviation for top dead center.

timing “ON” settings for critical press parameters like Auto Carry-up
Angle and Top Stop, and “ON” and “OFF” settings for cam
channels.

GL-6 Glossary
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

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°).

top stop constant A feature used to accommodate a press automation function at

WPC 2000. This feature works best on presses that have speed
ranges of several hundred to over a thousand strokes per minute.

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.

zero cam A closure-to-ground signal that turns on at approximately 270°

and turns off at 30°. Zero cam can be used with AutoSet load
monitors to “zero,” or clear, the current tonnage reading. Zero
cam is also used with RamPAC to check counterbalance air
pressure and with MultiPAC to increment the lube counter.

Glossary GL-7
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

GL-8 Glossary
Index
–A– –B–
AC wiring backup (tool and initialization data),
connecting to SmartPAC 2, 2-52 performing, 4-52
connecting to WPC 2000, 2-9 bar mode
grounding, 2-10, 2-53 fault, 7-11
running in conduit, 2-9, 2-52 mounting and wiring the control, 2-44
air pressure switch or sensor, installing and operating the press in, 6-52
wiring, 2-13 testing the control, 2-112
alerts (preventive maintenance) batch counters. See also counters
clearing, C-14 setting increment mode, 5-13
setting conditions for, C-10 setting output mode, 5-13
viewing, C-13 board (SmartPAC 2), installing replacement, G-1
alphanumeric tool numbers, setting, 4-7 board layouts
American National Standards Institute (ANSI), Cam Output, 2-66
extracts of standards, A-5 DiProPAC, 2-58
angle wheel rotation, setting, 4-6 DiProPAC installed on SmartPAC 2 board, 2-57
anti-repeat test, 2-97 ProCamPAC, 2-58
anti-tiedown test, 2-96 ProCamPAC installed on SmartPAC 2
auto advance board, 2-57
calculating the auto advance constant, 4-13 SmartPAC 2, 2-51
setting on/off angles for cam channels WPC 2000, 2-28
programmed as auto advance, 5-45 brake monitor
setting the auto advance constant, 4-14 adjusting parameters, 6-20
auto carry-up angle, setting, 4-28 faults, 7-3, 7-24
Auto Compensated Top Stop (ACTS) responding to brake warning LED, 7-3
enabling, 4-37 responding to stop time exceeded message, 7-4
setting the ACTS angle, 4-33 setting parameters, 4-30
auto enable brake warning LED
setting the auto enable by sensor counter, 5-23 location on SmartPAC 2 front panel, 1-7
setting the auto enable by tool counter, 5-21 responding to, 7-3
automatic continuous on-demand mode
enabling, 4-41 –C–
operating the press in, 6-51 cam channels
setting prior act time for, 4-38 adjusting programmed settings, 6-18
wiring, 2-46 deleting settings, 5-46
automatic single-stroke mode making an auto advance setting, 5-45
enabling, 4-41 naming, 4-10
operating the press in, 6-48 programming, 5-38
setting prior act time for, 4-38 programming a DSV on delay time, 5-46
wiring, 2-46 programming a timed output setting, 5-43
auxiliary equipment programming an on/off setting, 5-40
assigning names to, 4-24 programming multiple on/off settings, 5-41
faults, 7-14 setting global cams, 4-15
auxiliary E-stop output relay board, enabling the testing, 2-113
muting function, 4-42 viewing cam timing, 6-19
auxiliary outputs viewing the cam summary, 5-47, 6-20
change conditions, 2-35 viewing the global cam summary, 5-47, 6-20
setting aux. output 1 response to interrupted cam output assembly. See ProCamPAC output
stroke, 4-40 assembly
wiring, 2-35 cam output relays. See relays, cam output
checkout tests, performing, 2-88
CLEAR key (SmartPAC 2), using, 3-5
clock, setting, 4-64

Index IN-1
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

clutch air pressure setting rotational direction, 4-6

establishing low setpoint, 4-29 crankshaft angle window, opening, 6-6
installing and wiring sensor, 2-14 critical angle, setting for a sensor set to smart
installing and wiring switch, 2-15 stop, 5-26
viewing current pressure, 6-29 cross-checked inputs. See user inputs
viewing low setpoint, 6-29 cursor keys (SmartPAC 2)
communications using to highlight letters in entry windows, 3-7
faults, 7-31 using to increment/decrement numeric
performing a loopback test, 4-63 values, 3-7
setting parameters for Wintriss data collection using to move the highlight bar, 3-6
software, 4-55, H-7, I-7 using to set timing, 3-7
verifying, 4-62 custom names
viewing transmit and receive data, 4-63 creating for cam channels in Initialization
wiring, 2-52 mode, 4-12
concurrent time, setting for multiple op. creating for sensors in Initialization mode, 4-17
stations, 4-43 selecting for sensors in Program mode, 5-22
continuous mode cutout dimensions, SmartPAC 2 panel mount, 2-49
operating the press in automatic continuous on-
demand, 6-51 –D–
operating the press in continuous foot, 6-50 data collection software. See SFC
operating the press in continuous two-hand, 6-50 (ShopFloorConnect Asset Utilization Software)
testing with light curtain(s), 2-103 or LETS (Line Efficiency Tracking Software)
testing without light curtain(s), 2-106 date, setting, 4-64
control enclosure. See enclosure, WPC 2000 or DC power
enclosure, SmartPAC 2 specifications, 1-12
controls (Wintriss), connecting to WPC 2000, 2-34 wiring, 2-9, 2-115
counterbalance air pressure dead motor inch, operating the press in, 6-42
adjusting setpoint, 6-30 decimal places (tool information)
establishing setpoint, 5-49 formats, 4-22
establishing setpoint tolerance, 4-29 setting, 4-22
installing and wiring sensor, 2-14 delay time, setting for a DSV on cam channel, 5-46
installing and wiring switch, 2-15 diagnostics, setting menu items, 4-61
counters dimensions. See mounting dimensions
adjusting good parts count for reporting to diodes, installing, 2-69
LETS, I-23 DiPro Sensor Interface (DSI) 2, connecting sensors
adjusting good parts count for reporting to to, 2-61
SFC, H-25 DiProPAC. See also sensors (die protection)
adjusting in Program mode, 5-11 adding or upgrading, 2-56
adjusting in Run mode, 6-8 board layouts, 2-58
clearing the total hits counter, 5-12 installing new board, 2-59
entering preset values, 5-11 verifying installation, 2-74
entering scrap counts for reporting to LETS, I-20 display (SmartPAC 2)
entering scrap counts for reporting to SFC, H-23 layout, 3-13
preset reached messages, 7-23 selecting an item, 3-14
programming, 5-9 downtime, reporting to LETS, I-1
resetting batch counters, 6-8 downtime, reporting to SFC, H-1
setting batch pre-load counts, 5-15 DSV (Dual Safety Valve)
setting increment angle, 5-14 faults, 7-19, 7-31
setting increment mode for batch counters, 5-13 installing and wiring, 2-12
setting output mode for batch counters, 5-13 testing wiring, 2-91
setting parts per stroke or strokes per part, 5-14 DSV on cam channel, setting the delay time, 5-46
setting the auto enable by sensor counter, 5-23 dual light curtains, enabling, 4-38
setting the auto enable by tool counter, 5-21 dual operator stations
setting the strokes counter for a green special enabling, 4-41
sensor, 5-29 labelling, 2-22
crank angle clock wiring, 2-21
setting cam channel timing on, 5-40, 5-41, 5-43,
5-45
setting green sensor ready signal on, 5-29

IN-2 Index
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

–E– Shadow light curtain input faults, 7-18

tool programming faults, 7-27
e-mail
adding/changing messages in SmartView, E-14 top-stop and overrun setting faults, 7-21
top-stop circuit driver failure, 7-17
adding/changing recipient addresses in
viewing in the error/event log, 6-33
SmartView, E-14
enabling in Initialization, 4-57 firmware
downloading updated SmartPAC 2 firmware
enabling in SmartView, E-2
from Wintriss, D-7
sending messages, 6-36
sending messages to Wintriss Tech. Support, 6-37 installing updated SmartPAC 2 firmware, 4-65,
D-2
setting up in Initialization, 4-58
installing updated WPC 2000 firmware, 2-85
setting up in SmartView, E-2, E-14 ordering updated SmartPAC 2 firmware, D-1
emergency stop
flywheel speed
faults, 7-25
installing flywheel speed sensor, 2-43
setting as sensor stop type, 5-25 setting flywheel timer, 4-32
wiring emergency stop circuit, 2-54
foot switch
emergency-stop button (operator station)
enabling foot trip or foot control, 4-37
location, 1-8
operating the press in continuous foot, 6-50
testing emergency-stop circuit in continuous operating the press in single-stroke foot, 6-47
mode, 2-92
testing, 2-108
enable mode (sensor), setting, 4-18
wiring, 2-38
enclosure, SmartPAC 2 front panel (SmartPAC 2), components, 1-6
grounding AC wiring, 2-53
function keys (SmartPAC 2), using, 3-12
mounting, 2-47
enclosure, WPC 2000 –G–
grounding AC wiring, 2-10
mounting, 2-7 global cams
ENTER key (SmartPAC 2), using, 3-10 setting, 4-15
error messages. See faults viewing the global cam summary, 5-47, 6-20
error/event log good parts count, reporting to LETS, I-19
sending in an e-mail to Wintriss Tech. good parts count, reporting to SFC, H-22
Support, 6-37 green sensors
using to troubleshoot SmartPAC 2 adjusting the ready signal, 6-11
problems, 7-31 overview, 5-18
viewing, 6-33 programming the ready signal, 5-28, 5-32
Ethernet, connecting cable to SmartPAC 2, 2-55 selecting as sensor type, 5-24
events, viewing in the error/event log, 6-33 green special sensors
adjusting the stroke preset, 6-13
–F– programming the stroke preset, 5-29, 5-36
faults –H–
brake monitor faults, 7-3, 7-24
component failures, 7-14 HELP key (SmartPAC 2), using, 3-10
customized status codes, 7-14 Herion DSV, installing and wiring, 2-13
displaying multiple faults, 6-5 high-speed version of SmartPAC 2,
DSV and lockout relay failures, 7-19 configuring, 2-70
emergency-stop circuit driver failure, 7-17 hot keys
input buffer test failures, 7-13 deleting, 6-4
input check circuit faults, 7-24 overview, 3-12
internal memory failures, 7-23 programming, 6-3
internal timing input failures, 7-20 programming for dialog menu functions, H-21,
inter-processor failures, 7-12 I-18
light curtain faults, 7-16 toggling between two sets, 6-38
loss of rotation fault, 7-20 –I–
operational faults, 7-7
overrun limit switch faults, 7-21 inch mode
press control faults, 7-5 operating the press in dead motor inch, 6-42
resolver faults, 7-6, 7-24 operating the press in micro-inch, 6-42
responding to, 7-2 operating the press in top-stop bypass, 6-41
sensor faults, 7-28 operating the press in top-stop in inch, 6-41

Index IN-3
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

Info Center, 1-3 enabling light curtain break mode, 4-36

Initialization mode faults, 7-16, 7-18
entering and exiting, 4-2 increasing the safety distance for floating or
main menu, 4-2 blanking windows, 6-29
navigation, 3-18 installation requirements, 2-16, 2-22
overview, 3-17 installing non-Shadow light curtains, 2-23
input check circuit jumper settings (Shadow VII and Shadow
faults, 7-24 8), 2-23
running in conduit, 2-54 object sensitivity, 6-25
setting the voltage, 2-55 response times, 6-25
wiring, 2-54 testing safeguarding devices, 2-90
inputs, user. See user inputs testing Shadow light curtains, 2-98
installation guidelines, 2-3 link-motion press
installed options. See options (installed), viewing compensating for speed variation, 4-66
interlocks. See user inputs setting SmartPAC 2 for use with, 4-6, 4-65
interrupted stroke using a servofeed with, 4-66
responding to, 6-38 locked display, entering password to unlock, 6-4
setting auxiliary output 1 response to, 4-40 lockout
IP address, changing type in SmartView, E-4 clearing lockout message, 7-3
lockout relay faults, 7-19
–J– wiring lockout relay, 2-34
jumper settings, Shadow VII and Shadow 8, 2-23 loopback test, performing, 4-63

–K– –M–

key switch magnet (overrun limit sensor), mounting, 2-82

Program/Run, 3-11 main air pressure. See clutch air pressure
Stroke Select, 3-3 maximum press speed limit
wiring switch to prevent changes to WPC 2000 adjusting programmed value, 6-31
settings, 2-43 fault, 7-30
key(s), using programming, 5-50
CLEAR key, 3-5 messaging
cursor keys, 3-6 enabling in Initialization mode, 4-57
ENTER key, 3-10 sending a remote message in SmartView, E-13
function keys, 3-12 sending e-mail messages in SmartPAC 2, 6-36
HELP key, 3-10 micro-inch
hot keys, 3-12 enabling, 4-29, 6-39
number keys, 3-4 operating the press in, 6-42
RESET key, 3-11 setting micro-inch angle, 4-29
keyboard (computer), using to enter names, 4-68 setting micro-inch time, 4-29
keyboard (SmartPAC 2), using, 3-3 minimum press speed limit
adjusting programmed value, 6-31
–L– fault, 7-30
programming, 5-50
labels, dual operator station, 2-22 mounting dimensions
language, selecting, 4-9
one-hand control switch, 2-40, 2-41
latching magnetic cam switch (LMCS),
pre-wired operator station, 2-19
installing, 2-43 ProCamPAC output assembly, 2-65
LEDs
resolver, 2-26
brake warning LED location, 1-7
SmartPAC 2 enclosure, 2-47
LED indicator map, 2-89 SmartPAC 2 panel mount, 2-49
observing state in final checkout tests, 2-88
unwired operator station, 2-20
LETS (Line Efficiency Tracking Software)
WPC 2000 enclosure, 2-8
reporting downtime to, I-1 WPC 2000 mounting plate, 2-11
reporting good parts count to, I-19
multiple operator stations. See operator station(s)
reporting scrap count to, I-19
muting, enabling on auxiliary E-stop output relay
setting communications with SmartPAC 2, I-7 board, 4-42
light curtain(s)
enabling dual light curtains, 4-38

IN-4 Index
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

–N– mounting and wiring, 2-16

setting concurrent time for multiple op.
name(s)
assigning to auxiliary equipment, 4-24 stations, 4-43
setting palm time for one or two op.
assigning to tools, 5-9
stations, 4-43
creating custom names for cam channels, 4-12
creating custom names for sensors, 4-17 setting prior act time for automatic modes, 4-38
testing emergency-stop button in continuous
selecting for cam channels, 4-10
mode, 2-92
selecting for PM items, C-8
selecting for sensors, 5-22 testing top-stop button, 2-93
using multiple operator stations, 2-21, 6-53
setting for press, 4-10
wiring dual operator stations, 2-21
network
backing up tool settings to, 4-52 wiring unwired operator station, 2-20
Option 1. See user inputs
changing settings, 4-60, E-4
option switches
connecting SmartPAC 2 to, 2-55
programming settings, E-2 setting switches on S101, 4-35
setting switches on S102, 4-42
requirements for SmartView, E-1
options (installed), viewing, 4-9
setting up, 4-56, E-1
output mode, setting for batch counters, 5-13
new tool, loading, 6-34
ninety-degree (90°) stop-time test, performing, 6-20 outputs. See auxiliary outputs
overrun limit switch
number keys (SmartPAC 2), using, 3-4
displaying overrun sensor on/off angles, 6-31
numeric tool numbers, setting, 4-6
faults, 7-21, 7-22
–O– mounting sensor magnet, 2-82
mounting sensor switch, 2-30
object sensitivity, Shadow light curtains, 6-25 planning installation, 2-29
Occupational Safety and Health Administration setting top-stop "on" angle, 4-36
(OSHA), extracts of regulations, A-1 viewing angle at which top-stop cam turns
one-hand control off, 6-31
enabling light curtain break mode, 4-36 wiring sensor switch, 2-31
mounting, 2-40
single-stroke operation, 6-45 –P–
testing, 2-110
palm time, setting for one or two op. stations, 4-43
using in light curtain break mode, 2-39, 6-45
panel mount, SmartPAC 2
wiring to WPC 2000, 2-41
one-hand single-stroke mode, operating the press installing, 2-48
mounting and cutout dimensions, 2-49
in, 6-44
parameters (press)
operating mode, SmartPAC 2
entering and exiting, 3-16 initializing, 2-75, 4-34
setting, 4-27
Initialization mode, 3-17
password
overview, 3-15
Program mode, 3-19 assigning a new PM monitor password, C-8
changing defaults, 4-50
Run mode, 3-21
checking, 4-50
operating mode, WPC 2000
running the press in bar mode, 6-52 entering the PM monitor password, C-4
entering to unlock a protected screen, 4-49, 6-4
running the press in continuous, 6-49
lost or forgotten password, 4-49
running the press in inch, 6-40
running the press in single-stroke, 6-42 ping utility, using in SmartView, E-15
power supply, testing, 2-90
setting, 4-40
power, turning on to SmartPAC 2, 2-71
wiring outputs, 2-37
operator station(s) Precision Metalforming Association (PMA),
interpretation of OSHA regulations, A-1
anti-repeat test, 2-97
presets (counter)
anti-tiedown test, 2-96
building your own operator station, 2-21, B-1 preset reached messages, 7-23
setting and clearing, 5-11
checking wiring of pre-wired operator
press
station, 2-17
components, 1-8 adjusting counterbalance setpoint, 6-30
adjusting speed limits, 6-30
enabling dual operator stations, 4-41
adjusting top-stop "on" angle, 6-29
installing multiple operator stations, 2-21
labelling dual operator stations, 2-22 selecting press type in SmartView, E-2

Index IN-5
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

selecting pressure units, 4-33 wiring, 2-64

setting counterbalance setpoint, 5-49 Program mode
setting flywheel timer, 4-32 entering and exiting, 5-1
setting low setpoint for clutch air pressure, 4-29 main menu, 5-1
setting operator mode, 4-40 navigation, 3-20
setting option switches on S101, 4-35 overview, 3-19
setting option switches on S102, 4-42 Program/Run key switch, using, 3-11
setting press name, 4-10 pulse
setting press parameters, 4-27 setting batch counter output mode to, 5-13
setting press type, 4-60 setting duration of pulsed batch counter
setting shutdown time, 4-32 output, 5-13
setting SmartPAC 2 for use with a link-motion
press, 4-65 –R–
setting speed limits, 5-49 ready signal
setting the start time limit, 4-32 adjusting for a green sensor, 6-9
setting the stop time limit, 4-30 overview, 5-17
setting tolerance for counterbalance programming for a green sensor, 5-28, 5-32
setpoint, 4-29 red sensors
viewing status of user inputs, 4-44 faults, 7-30
viewing the start time, 6-20 overview, 5-18
viewing the start time limit, 6-20 selecting as sensor type, 5-24
viewing the stop time, 6-20 relay, lockout. See lockout
viewing the stop time limit, 6-20 relays, cam output
viewing the stopping angle, 6-20 connecting to equipment, 2-68
pressure switch or sensor. See air pressure switch or installing diodes, 2-69
sensor installing suppressors, 2-69
pressure units, selecting, 4-33 selecting for each channel, 2-64
preventive maintenance (PM) monitor remote messages, sending in SmartView, E-13
assigning a new password, C-8 remote reset switch, wiring, 2-70
clearing an alert, C-14 RESET key (SmartPAC 2), using, 3-11
entering the password, C-4 resolver
initializing, C-6 faults, 7-6, 7-24
installing, C-3 mounting, 2-25
making Initialization settings, C-4 principle of operation, 1-6
modifying the tracking frequency in Run running wiring in conduit, 2-50
mode, C-14 setting direction of rotation, 2-77
operation, C-2 wiring, 2-25, 2-50
selecting PM item names, C-8 zeroing, 2-78, 4-3
setting tracking frequency, C-11 response times, Shadow light curtains, 6-25
setting tracking units, C-10 restore (tool and initialization data),
using in Run mode, C-12 performing, 4-52
viewing PM status, C-13 Ross DSV
prior act time, setting for automatic modes, 4-38 installing and wiring, 2-12
ProCamPAC resetting faults (DM2), 7-31
adding or upgrading, 2-56 Run mode
board layouts, 2-58 entering and exiting, 6-2
installing new board, 2-59 main menu, 6-1
replacing board, 2-57 navigation, 3-22
testing cam channels, 2-113 overview, 3-21
verifying installation, 2-74
ProCamPAC output assembly –S–
board layout, 2-66
connecting relays to equipment, 2-68 safeguarding devices, testing, 2-90
safety distance
installing diodes, 2-69
calculating using the ANSI formula, 6-25
mounting, 2-64
mounting dimensions, 2-65 calculating using the OSHA formula, 6-27
increasing for floating or blanking windows, 6-29
running wiring in conduit, 2-64
selecting relays for cam channels, 2-64

IN-6 Index
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

SBR (SmartPAC Backup and Restore) single-stroke mode

using to back up tool settings in SmartPAC 1, F-1 operating the press in automatic single-
using to restore SmartPAC 1 tool settings to stroke, 6-48
SmartPAC 2, F-12 operating the press in single-stroke foot, 6-47
scrap count, reporting to LETS, I-19 operating the press in single-stroke one-
scrap count, reporting to SFC, H-22 hand, 6-44
screens (SmartPAC 2) operating the press in single-stroke two-
e-mailing screen captures, 3-23 hand, 6-43
layout, 3-13 operating the press with a one-hand control, 6-45
making screen captures, 3-23 testing with light curtain(s), 2-99
security testing without light curtain(s), 2-102
access settings, 4-48 slow RPM, setting, 4-13
access types, 4-47 smart stop, setting as sensor stop type, 5-25
changing passwords, 4-50 SmartPAC 1, upgrading to SmartPAC 2, F-1
setting access privileges, 4-50 SmartPAC 2 board layout, 2-51
wiring a keylock switch to prevent changes to SmartView
WPC 2000 settings, 2-43, 4-52 changing IP address type, E-4
sensor summary, viewing, 5-31 changing network settings, E-4
sensor-disabled output, wiring, 2-70 enabling, 4-58, E-2
sensors (die protection) enabling e-mail, E-2
adjusting the ready signal for green sensors, 6-9 installing, E-6
adjusting the stroke preset for green special network requirements, E-1
sensors, 6-9 operation, E-10
changing sensor settings, 5-30 programming network settings, E-2
deleting a sensor, 5-31 selecting press type, E-2
enabling/disabling, 5-52, 6-6 sending remote messages, E-13
faults, 7-28 setting up e-mail, E-2
naming, 5-22 setting up the network, E-1
programming, 5-16, 5-20, 5-32, 5-36 using the main page, E-11
programming the ready signal for green using the ping utility, E-15
sensors, 5-28, 5-32 using the press status information page, E-12
programming the stroke preset for green special using the setup page, E-10
sensors, 5-29, 5-36 specifications, SmartPAC 2, 1-12
sensor terminology, 5-16 speed (press)
sensors available from Wintriss, 1-10 adjusting programmed maximum and minimum
setting enable mode, 4-18 limits, 6-30
setting sensor type, 5-24 configuring high-speed version of SmartPAC
setting stop type, 5-25 2, 2-70
setting the auto enable by sensor counter, 5-23 faults, 7-30
setting the auto enable by tool counter, 5-21 programming maximum and minimum
setting the critical angle for sensors set to smart limits, 5-49
stop, 5-26 start time
turning a sensor on or off, 5-53 fault (loss of rotation), 7-20
types, 5-17 viewing, 6-20
viewing actual on/off angles, 6-11 start time limit
viewing sensor settings, 5-30 setting, 4-31
viewing sensor status, 5-52, 6-14 viewing, 6-20
viewing the sensor summary, 5-31, 6-13 startup problems, 2-73
setup mode status (sensor), viewing, 5-52, 6-14
enabling, 4-19 stop circuits
enabling/disabling counters, 4-8 running in conduit, 2-54
SFC (ShopFloorConnect Asset Utilization wiring, 2-54
Software) stop time
reporting downtime to, H-1 determining using the ninety-degree (90°) stop-
reporting good parts count to, H-22 time test, 6-20
reporting scrap count to, H-22 faults, 7-3, 7-26
setting communications with SmartPAC 2, H-7 viewing, 6-20
shutdown time, setting, 4-32

Index IN-7
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

stop time limit top-stop button (operator station)

calculating, 4-31 location, 1-8
setting, 4-30 testing top-stop circuit, 2-93
viewing, 6-20 top-stop bypass, operating the press in, 6-41
stop type (sensor), setting, 5-25 top-stop in inch, operating the press in, 6-41
stopping angle, viewing, 6-20 top-stop mode for F and H errors, setting, 4-39
stroke preset tracking frequency (preventive maintenance)
adjusting for a green special sensor, 6-9 modifying, C-14
programming for a green special sensor, 5-29, setting, C-11
5-36 tracking units (preventive maintenance),
Stroke Select key switch, using, 3-3 setting, C-10
suppressors, installing, 2-69 two-hand mode
system static test, 2-93 operating the press in continuous two-hand, 6-50
operating the press in single-stroke two-
–T– hand, 6-43
test tool, creating and loading, 2-76 two-hand only operating mode, enabling, 4-41
tests. See checkout tests
–U–
time, setting, 4-64
toggle, setting batch counter output mode to, 5-13 units (tool information), abbreviations, 4-22
tool information upgrade, SmartPAC 1 to SmartPAC 2, F-1
abbreviations for units, 4-22 USB disk
changing tool parameters, 6-32 backing up and restoring tool settings, 4-52
decimal place formats, 4-22 saving SmartPAC 2 information to, 4-65
entering tool parameters, 5-50 user inputs
setting formats for, 4-19 fault codes, 2-33, 7-15, J-10
tool number mode, setting, 4-6 setting input name, 4-24
tool template, copying to a new tool, 5-5 setting stop type, 4-24, J-8
tool(s) testing, 2-113
assigning names to, 5-9 viewing status, 4-44, J-9
backing up SmartPAC 2 settings, 4-52 wiring, 2-31, J-5
backing up/restoring SmartPAC 1 settings to
SmartPAC 2, F-1 –W–
changing settings, 5-6 wiring
copying settings from an existing tool to a new general recommendations, 2-3
tool, 5-4 running in conduit, 2-3
copying tool template to a new tool, 5-5 wiring connections
creating a new tool, 5-3 AC power, 2-52
creating and loading a test tool, 2-76 automatic single-stroke, 2-46
deleting a tool, 5-7 Aux I/O (SmartPAC 2), 2-116
entering tool information, 5-50 auxiliary e-stop relay board (WPC 2000), 2-115
loading a new tool in Program mode, 5-5 auxiliary outputs, 2-35
loading a new tool in Run mode, 6-34 bar control, 2-45
loading a tool to access Run mode, 6-2 communications, 2-52
programming, 5-8 DC power (WPC 2000), 2-115
restoring SmartPAC 2 settings, 4-54 DSV/lockout relay board (WPC 2000), 2-34,
tool programming faults, 7-27 2-115
top stop flywheel speed sensor (LMCS), 2-44
setting as sensor stop type, 5-25 foot switch, 2-38
setting batch counter output mode to top input check circuit, 2-54
stop, 5-13 one-hand control, 2-42
wiring top stop circuit, 2-54 overrun sensor switch, 2-31
top-stop "on" angle ProCamPAC output assembly, 2-64
adjusting angle, 5-48, 6-29 remote reset switch, 2-70
calculating angle, 2-79 resolver (SmartPAC 2 TB101), 2-51
setting angle, 2-79, 4-28 resolver (WPC 2000 TB106), 2-27
setting angle range, 4-36 sensor-disabled output, 2-70
SFI and Module ports (SmartPAC 2), 2-115
Spare 1 and WPC ports (SmartPAC 2), 2-116

IN-8 Index
SmartPAC 2 with WPC 2000 Integration User Manual 1128600

Spare 3 and 4 ports (SmartPAC 2), 2-116 –Y–

Special and PACNet ports (SmartPAC 2), 2-115
yellow sensors
stop circuits, 2-54 faults, 7-29
user inputs, 2-33, 7-15, J-6
overview, 5-18
WPC 2000 main processor board (TB101-
selecting as sensor type, 5-24
TB104), 2-114
WPC 2000 board layout, 2-28

Index IN-9
1128600 SmartPAC 2 with WPC 2000 Integration User Manual

IN-10 Index
Wintriss Manuals
Installation User Manual/CD
Wintriss Product Manual Doc. No. Doc. No.
AutoSet (1500, 1500 Plus, 1504, 1504 Plus) DA71747 DA71447
AutoSetPAC (Tonnage Monitor) DA71413 DA71443
Die Protection Handbook N.A. * 1130300 *
DiPro 1500 DA71428 DA71447
DSI 2 Sensor Interface N.A. * DA66970 *
LETS Machine Interface (LMI) N.A. ** DA71974 **
MultiPAC Types 1 and 2 DA71409 DA71443
MultiPAC Types 4 and 5 DA71410 DA71443
ProCam 1500 DA71430 DA71447
ProPAC (Process Monitor-In-die Measurement) DA71411 DA71443
RamPAC (Shut Height, Counterbalance & DA71412 DA71443
Cushion Control)
Servofeed Interface-Coe/Wintriss DA71415 DA71443
Servofeed Interface-CWP/Wintriss DA71416 DA71443
Servofeed Interface-DiPro DA71429 DA71447
Servofeed Interface-Electrocraft/Wintriss DA71417 DA71443
Servofeed Interface-Indramat/Wintriss DA71418 DA71443
Servofeed Interface-ProCam DA71431 DA71447
Servofeed Interface-SmartPAC DA71420 DA71443
Servofeed Interface-Waddington/Wintriss DA71419 DA71443
SFC Machine Interface (SMI) N.A. ** 1140800**
Shadow V Safety Light Curtain DA71433 DA71449
Shadow VI Safety Light Curtain DA71422 DA71445
Shadow VII Safety Light Curtain N. A. * 1129400 *
Shadow 8 Safety Light Curtain N. A. * 1139300 *
SmartPAC (w/ DiProPAC & ProCamPAC) DA71439 DA71454
SmartPAC Hydraulic DA71435 DA71451
SmartPAC Run Mode (Spanish) N. A. * DA71443 *
SmartPAC w/ WPC II Integration DA71440 DA71455
SmartPAC 2 (w/ DiProPAC & ProCamPAC) DA71406 DA71441
SmartPAC 2 Hydraulic DA71436 DA71451
SmartPAC 2 Servo DA71437 DA71452
SmartPAC 2 w/ WPC 2000 Integration DA71407 DA71442
SmartPAC 2 w/WPC 2000 Run Mode (Spanish) N. A. * DA71443
WaveFormPAC (Advanced Load Analyzer) DA71414 DA71443
Wintriss Brake Monitor DA71432 DA71448
Wintriss Clock Display N. A. * DA67206 *
WPC II Wintriss Press Control DA71438 DA71453
WPC 1000 Wintriss Press Control DA71423 DA71446
WPC 2000 Wintriss Press Control DA71421 DA71444
WPC 2000 Option 2 DA71408 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 with WPC 2000 Setup Sheet
Tool Name and Number:

Counter Presets

Batch 1 (Ch. 6) Batch 2 (Ch. 7) Batch 3 (Ch. 8)

Preset Value

Top Stop Top Stop Top Stop

Output mode
Toggle Toggle Toggle
(circle one)
Pulse for _______mS Pulse for _______mS Pulse for _______mS

Increment mode Strokes Strokes Strokes

(circle one) Good Parts Good Parts Good Parts

Increment angle
(degrees)

This tool should be serviced when the TOTAL HITS count reaches

Strokes / Part: - OR - Parts / Stroke:

Tool Information

Item Value Units

Tool Memo box text __ __ __ __ __ __ __ __ __ __ __ __ __ __ __

(30 characters, total):
__ __ __ __ __ __ __ __ __ __ __ __ __ __ __
ProCamPAC Cam Switch – SmartPAC 2 Setup Sheet
Channels 1 - 8
Tool Name and Number:

Ch. # Cam Name (function) Global Auto TIMED DSV-ON ON/OFF

same for all tools cam? Adv.? 4 max. Time to Multiple arcs for ON/OFF
( ) ( ) ON angle shut-off only.
+ after 6 extras, total
Not Ch. 2 max. ON Time press Arc # ON OFF
6, 7 or 8 in mS stops, in Normally 1
Program angle angle
seconds arc per
ON/OFF
angles channel,
can be up
to 4
1 Arc 1
° sec Arc 2
Arc 3
mS
Arc 4
2 Arc 1
° sec Arc 2
Arc 3
mS
Arc 4
3 Arc 1
° sec Arc 2
Arc 3
mS
Arc 4
4 Arc 1
° sec Arc 2
Arc 3
mS
Arc 4
5 Arc 1
° sec Arc 2
Arc 3
mS
Arc 4
6 Arc 1
° sec Arc 2
Arc 3
mS
Arc 4
7 Arc 1
° sec Arc 2
Arc 3
mS
Arc 4
8 Arc 1
° sec Arc 2
Arc 3
mS
Arc 4
ProCamPAC Cam Switch – SmartPAC 2 Setup Sheet
Channels 9 - 16
Tool Name and Number:

Ch. # Cam Name (function) Global Auto TIMED DSV-ON ON/OFF

same for all tools cam? Adv.? 4 max. Time to Multiple arcs for ON/OFF
ON angle shut off only.
( ) ( ) + after 6 extras, total
press
2 max. ON time Arc # ON OFF
in mS stops, Normally 1
angle angle
Program in arc per
seconds channel,
ON/OFF
can be up
angles
to 4
9 Arc 1
° sec Arc 2
Arc 3
mS
Arc 4
10 Arc 1
° sec Arc 2
Arc 3
mS
Arc 4
11 Arc 1
° sec Arc 2
Arc 3
mS
Arc 4
12 Arc 1
° sec Arc 2
Arc 3
mS
Arc 4
13 Arc 1
° sec Arc 2
Arc 3
mS
Arc 4
14 Arc 1
° sec Arc 2
Arc 3
_____ms
Arc 4
15 Arc 1
° sec Arc 2
Arc 3
mS Arc 4
16 Arc 1
° sec Arc 2
Arc 3
mS
Arc 4
DiProPAC Die Protection – SmartPAC 2 Setup Form
Sensors 1-16
Tool Name and Number:
Sensor Sensor Name Sensor Type Stop Type Ready Signal
Number (function) (circle one) (circle one) Timing
1 G R Y E-STOP ON
GC GQ TOP STOP
GS ______strokes SMART STOP OFF

2 G R Y E-STOP ON
GC GQ TOP STOP
GS ______strokes SMART STOP OFF

3 G R Y E-STOP ON
GC GQ TOP STOP
GS ______strokes SMART STOP OFF

4 G R Y E-STOP ON
GC GQ TOP STOP
GS ______strokes SMART STOP OFF

5 G R Y E-STOP ON
GC GQ TOP STOP
GS ______strokes SMART STOP OFF

6 G R Y E-STOP ON
GC GQ TOP STOP
GS ______strokes SMART STOP OFF

7 G R Y E-STOP ON
GC GQ TOP STOP
GS ______strokes SMART STOP OFF

8 G R Y E-STOP ON
GC GQ TOP STOP
GS ______strokes SMART STOP OFF

9 G R Y E-STOP ON
GC GQ TOP STOP
GS ______strokes SMART STOP OFF

10 G R Y E-STOP ON
GC GQ TOP STOP
GS ______strokes SMART STOP OFF

11 G R Y E-STOP ON
GC GQ TOP STOP
GS ______strokes SMART STOP OFF

12 G R Y E-STOP ON
GC GQ TOP STOP
GS ______strokes SMART STOP OFF

13 G R Y E-STOP ON
GC GQ TOP STOP
GS _____strokes SMART STOP OFF

14 G R Y E-STOP ON
GC GQ TOP STOP
GS ______strokes SMART STOP OFF

15 G R Y E-STOP ON
GC GQ TOP STOP
GS ______strokes SMART STOP OFF

16 G R Y E-STOP ON
GC GQ TOP STOP
GS ______strokes SMART STOP OFF

Auto Enable Counter Critical Angle X ° (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 Sensor Name Sensor Type Stop Type Ready Signal
Number (function) (circle one) (circle one) Timing
17 G R Y E-STOP Linked to
GC GQ TOP STOP
GS ______strokes SMART STOP Sensor #____
18 G R Y E-STOP Linked to
GC GQ TOP STOP
GS ______strokes SMART STOP Sensor #____
19 G R Y E-STOP Linked to
GC GQ TOP STOP
GS ______strokes SMART STOP Sensor #____
20 G R Y E-STOP Linked to
GC GQ TOP STOP
GS ______strokes SMART STOP Sensor #____
21 G R Y E-STOP Linked to
GC GQ TOP STOP
GS ______strokes SMART STOP Sensor #____
22 G R Y E-STOP Linked to
GC GQ TOP STOP
GS ______strokes SMART STOP Sensor #____
23 G R Y E-STOP Linked to
GC GQ TOP STOP
GS ______strokes SMART STOP Sensor #____
24 G R Y E-STOP Linked to
GC GQ TOP STOP
GS ______strokes SMART STOP Sensor #____
25 G R Y E-STOP Linked to
GC GQ TOP STOP
GS ______strokes SMART STOP Sensor #____
26 G R Y E-STOP Linked to
GC GQ TOP STOP
GS ______strokes SMART STOP Sensor #____
27 G R Y E-STOP Linked to
GC GQ TOP STOP
GS ______strokes SMART STOP Sensor #____
28 G R Y E-STOP Linked to
GC GQ TOP STOP
GS ______strokes SMART STOP Sensor #____
29 G R Y E-STOP Linked to
GC GQ TOP STOP
GS _____strokes SMART STOP Sensor #____
30 G R Y E-STOP Linked to
GC GQ TOP STOP
GS ______strokes SMART STOP Sensor #____
31 G R Y E-STOP Linked to
GC GQ TOP STOP
GS ______strokes SMART STOP Sensor #____
32 G R Y E-STOP Linked to
GC GQ TOP STOP
GS ______strokes SMART STOP Sensor #____

Auto Enable Counter Critical Angle X ° (for Smart Stop)

G=GREEN STD; R=RED; Y=YELLOW; GC=GREEN CONSTANT; GQ=GREEN QUICK CHECK; GS=GREEN SPECIAL
 SmartPAC Initialization Setup Sheet
Initialization Menu Item Initialization Setting Options
Position Sensor Position Sensor Mode Enabled
Disabled
Counter Setup Mode Not incremented in Inch mode
Is incremented in all modes
Installed Options (e.g., PM
Monitor, Feed Control, Press
Control, Lube/Speed Control)
Press Name
Set Brake Monitor Stop Time Limit msec
Start Time Limit msec
Select Cam Names Channel 1
Channel 2
Channel 3
Channel 4
Channel 5
Channel 6
Channel 7
Channel 8
Channel 9
Channel 10
Channel 11
Channel 12
Channel 13
Channel 14
Channel 15
Channel 16
Auto Advance Advance Constant 1
Advance Constant 2
Top Stop Constant
Slow RPM
Custom Sensor Names Custom 1
Custom 2
Custom 3
Custom 4
Custom 5
Custom 6
Custom 7
Custom 8
Custom 9
Custom 10
 SmartPAC Initialization Setup Sheet (Page 2)
Initialization Menu Item Initialization Setting Options
Custom Sensor Names (cont.) Custom 11
Custom 12
Custom 13
Custom 14
Custom 15
Custom 16
Sensor Enable Mode Sensor Enable Mode Manual Enable
Auto by Tool
Auto by Sensor
Tool Information Tool 1 Name
Units
Places
Tool 2 Name
Units
Places
Tool 3 Name
Units
Places
Tool 4 Name
Units
Places
Tool 5 Name
Units
Places
Tool 6 Name
Units
Places
 SmartPAC Initialization Setup Sheet (Page 3)
Initialization Menu Item Initialization Setting Options
Security Access Load Tool # Program and Run Modes
Program Mode Only
Password Required
Delete Tool # Program Mode
Password Required
Not Allowed
Set Counter Preset Program and Run Modes
Program Mode Only
Password Required
Change Count Program and Run Modes
Program Mode Only
Password Required
Reset Mode Program and Run Modes
Program Mode Only
Password Required
Adjust Sensors Program and Run Modes
Program Mode Only
Password Required
Disable Sensors Program and Run Modes
Program Mode Only
Password Required
Turn Off Sensors Password Required
Allowed
Not Allowed
Adjust Cams Program and Run Modes
Program Mode Only
Password Required
Adjust Feed Program and Run Modes
Program Mode Only
Password Required
Adjust Tool Info Program and Run Modes
Program Mode Only
Password Required
Initialize Password Must Be Used
Not Required
Set Passwords Menu Init. Password
General Password
 Press Parameters Setup Sheet
Press Parameters
(INITIALIZATION–PRESS CONTROL–PRESS PARAMETERS)

Parameter Setting
TOP STOP DEFLT
CARRYUP ANGLE
MICRO TIME [ONLY WITH MICRO-INCH]
MICRO ANGLE [ONLY WITH MICRO-INCH]
MAIN AIR LIMIT
CNTR BAL +/–
STOP LIMIT
START LIMIT
SHUT DOWN TIME
FLYWHEEL TIMER
ACTS ANGLE [ONLY WITH AUTO
COMPENSATED TOP STOP OPTION]
PRESSURE UNITS

Press Control Option Switches and Other Mode Settings

(INITIALIZATION–PRESS CONTROL–PRESS OPTIONS)

These are set to OPEN when you Circle current setting

initialize press parameters.
DUAL OPERATORS SCREEN MODE
Circle current setting REMOTE SWITCH
NOT USED
Switch 1 OPEN
CLOSED AUTOMATIC MODE ENABLED
DISABLED
Switch 2 OPEN
CLOSED TWO HAND ONLY ENABLED
DISABLED
Switch 3 OPEN
CLOSED
Switch 4 OPEN
CLOSED
Switch 5 OPEN
CLOSED
Switch 6 OPEN
CLOSED
Switch 7 OPEN
CLOSED
Switch 8 OPEN
CLOSED
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