3rd Party Comms Instructions - Wintriss

SmartPAC - Enhanced 3rd Party Communications Instructions 1138700D
Instruction Sheet:
SmartPAC 2 and SmartPAC PRO Enhanced Third-Party
Communications Firmware
The SmartPAC Third Party Communications Firmware option enables SmartPAC 2 and
SmartPAC PRO to transmit real-time status information to external software systems. It
includes the following features:
• SmartPAC Dialog mode, which allows operators to assign reasons to downtime events
from a SmartPAC Run mode menu (refer to Page 14).
• MODBUS protocol (MODBUS TCP) to transfer data to external systems. SmartPAC 2
and SmartPAC PRO communicates via its built-in Ethernet port.
• Fourteen (14) standard tags and 188 expanded data tags to transport the data over the
Ethernet via MODBUS TCP (see Tables 1, 2, and 3). Each data tag represents a
production parameter. The information stored in each tag is continuously overwritten
during production and must be polled at regular intervals to make this data available to
the remote system.
A MODBUS “master” installed on the remote server oversees the polling process. The
MODBUS master transmits queries over the Ethernet to SmartPAC, and the MODBUS
protocol on that machine, referred to as the MODBUS “slave,” responds by transmitting all
tags with their current data.
Wintriss recommends that Kepware ServerEX by Kepware Technologies be used as the
MODBUS master (get info at www.kepware.com). A file containing a MODBUS Tag
Assignment List - which provides all of the tags used by the SmartPAC to transfer data - is
available for download at www.wintriss.com/comms/. The file can be imported directly
into Kepware as an .OPF document.
NOTICE
To ensure that the .OPF document imports correctly into Kepware, do not make changes to
the file. The file contains a number of empty columns.
Download the file at Wintriss Download Center
(https://wintriss.com/wcg/general/downloads.html)
SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 1

Changing from the System Default DHCP to Static IP Address

The SmartPAC 2 and SmartPAC PRO come from the factory set up for a Dynamic Host Configuration
Protocol (DHCP) network, which automatically assigns IP addresses. We strongly recommend that you
reconfigure your SmartPAC 2 or SmartPAC PRO to use a static (fixed) IP address when using the
Enhanced 3rd-Party Communications Firmware. You will need to connect a standard USB mouse to
the SmartPAC 2 in order complete this conversion.
The method for reconfiguring your SmartPAC 2 depends on the operating system (XPE) version
installed in your system. For XPE versions less than 3.4 follow the steps below. For XPE versions 4.0
and greater follow the steps in the next section.
To determine which XPE version you have, go to the Installed Options Menu by turning the PROG/RUN
key to Program, then press the 1 and Clear keys simultaneously and select INSTALLED OPTIONS.
For XPE < 3.04 follow these steps:
1. Power down the SmartPAC 2.

2. Open the enclosure. Access the USB (J117) connector on the SmartPAC 2 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 by holding down the “1” and “CLEAR” keys simultaneously
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.
11. In the Local Area Connection Properties window, select Internet Protocol (TCP/IP) and single-
left-click on the Properties button. The Internet Protocol (TCP/IP) Properties window displays
with two radio buttons already selected: “Obtain an IP address automatically” and “Obtain
DNS server address automatically.” These are the default settings to make your SmartPAC 2
DHCP-enabled.
12. Single-left-click once to select “Use the following IP address,” and single-left click again to
select “Use the following DNS server address.”
13. Using the on-screen keyboard, enter the appropriate IP addresses. Consult your IT department
if you need help.
14. Single-left-click on the “OK” button.

15. Close the On-Screen Keyboard, Local Area Connection Properties, and Network Connections
windows. You should see a blank blue screen with a small window labeled Control Panel
entered with the words Re-Start System and Save Changes. Single-left click on the OK button
to restart the SmartPAC 2 and save your new network settings.
For XPE > 3.04 follow these steps:
1. Power down the SmartPAC 2 and connect a USB mouse to the USB connector.
2. 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.
3. Turn the PROG/RUN key switch to PROG, then access the Main Initialization Menu by holding
down the “1” and “CLEAR” keys simultaneously and select “SETUP NETWORK”.
4. On the Network Setup Utility screen, select “CHANGE NETWORK SETTINGS”.
5. 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.
6. When the Control Panel “Pick a category” screen appears, single-left-click on “Network and
Internet Connections”.
7. Single-right-click on “Network Connections” under “or pick a Control Panel icon”.
8. Single-right-click on the Local Area Connection icon.
9. Single-left-click on Properties in the drop-down box that displays. A Window should appear
labelled “Local Area Connection Properties”.
10. 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.
11. Single-left-click once to select “Use the following IP address,” and single-left click again to
select “Use the following DNS server address.”
12. Using the on-screen keyboard, enter the appropriate IP addresses. Consult your IT department
if you need help.
13. Single-left-click on the OK button.
14. 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.

For SmartPAC PRO follow these steps:
The SETUP NETWORK item on the Main Initialization Menu allows you to set up SmartPAC
PRO’s E-mail and SmartView functions and to make other settings necessary to configure a
SmartPAC PRO network. You make these settings on the Network Setup Utility screen (see Figure
1-1).
Figure 1-1. Network Setup Utility

Table 1 – Standard Data Tag List
MODBUS
Tag Value
Register Length Range
Number
Tag Name/Description
Production_Good_Parts_PRESET 401001 DWord 1-9,999,999
(32-bit)
Reports the SmartPAC Good Parts Counter PRESET value
entered by the operator.
Production_Tool_Number * 401003 DWord 1-9,999,999
(32-bit)
Reports the tool number currently loaded in the
SmartPAC.
Production_Job_Number * 401005 DWord 1-9,999,999
(32-bit)
Reports the operator-entered job number currently
loaded in the SmartPAC.
Production_Part_Number * 401007 DWord 1-9,999,999
(32-bit)
Reports the operator-entered part number currently loaded in
the SmartPAC.
Counter_Strokes_No_”RESET” 401009 DWord 0-16,777,216
(32-bit)
Reports the total number of strokes made by the press.
Increments when the SmartPAC Strokes Counter
increments until it reaches a limit of 2^24, or 16,777,216;
then, it starts counting again from 0. The counter cannot
be “RESET” at the SmartPAC.
Counter_Good_Parts_No_”RESET” 401011 DWord 0-16,777,216

(32-bit)
Reports the total number of good parts made by the press.
Increments when the SmartPAC Good Parts Counter
increments until it reaches a limit of 2^24, or 16,777,216;
then, it starts counting again from 0. The counter cannot be
“RESET” at the SmartPAC.
Press_Stop_Time_Actual 401013 Word 0-9,999

(16-bit)
Reports the most recent stopping time of the press (in
milliseconds) measured by the SmartPAC.
Press_Stop_Time_Limit 401014 Word 0-9,999
(16-bit)
Reports the stop time limit (in milliseconds) set in SmartPAC
Initialization. Refer to the SmartPAC User Manual for
information on this setting.
Press_Total_Tonnage 401015 Word 0.0-999
Reports the total forward peak load on the press for (16-bit)
SmartPAC systems equipped with AutoSetPAC or
WaveFormPAC. This value is calculated by adding the
peak tonnage on all tonnage monitor inputs. If no
tonnage monitor is present, the value is set to 0.

Table 1 – Standard Data Tag List (Cont.)
Press_Shaft_Speed 401016 Word (16- 0-9,999

bit)
Reports the current speed of the press if Single-stroke mode is
disabled in SmartPAC Initialization; reports the calculated
production rate if Single- stroke mode is enabled. Refer to
document #1137900 for an explanation of this setting.
Press_Operator_1 401019 DWord 0-9,999,999

(32-bit)
Reports the Operator Number, entered at the SmartPAC,
of the current operator.
Counter_Scrap_No_”RESET” 401021 Word 0-32,767

(16-bit)
Reports the total number of scrap items entered at the
SmartPAC. Increments until it reaches a limit of 2^15, or
32,767; then, it starts counting again from 0. The counter
cannot be “RESET” at the SmartPAC.
Press_State_Code 401022 Word 1-7

(16-bit)
Reports the current machine state of the SmartPAC (refer
to page 6 for an explanation of machine states). Values
are:
1 Running
2 Not used
3 Not used
4 Unplanned downtime
5 Changeover
6 Idle
7 Planned downtime
Press_Error_Reason_Code 401023 Word 0-9,999
(16-bit)
Reports the error code representing the current error
displayed at the SmartPAC or the current downtime reason
entered by the operator (see document
#1137900). Error codes and corresponding errors are shown
in Tables 3 (page 9) and 5 (page 25). The following codes
represent Press_State_Code values (i.e., machine states):
0 Press_State_Code = 1 or 6 (Running or Idle)
222 Press_State_Code = 5 (Changeover)
238 Press_State_Code = 7 (Planned downtime)
* When a new tool is loaded at the SmartPAC, this value will “RESET” to zero and remain at zero for five seconds,
then increment to its new, correct value.

Table 2 – Expanded Data Tag List
EXPANDED - Counter Tags
Good parts counter 400003 Dword

Stroke counter 400001 Dword
Stroke counter preset 400007 Dword
Batch 1 counter 400005 Dword
Batch 1 preset 400011 Dword
Total hits for tool 400031 Dword
Total hits preset 400443 Dword
EXPANDED - Scheduling Tags
Alphanumeric Job String 401028 String (14 Char Max)

Alphanumeric Part String 401036 String (26 Char Max)
Production Write String (writeable tag)* 401050 String (240 Char Max)
* This is used to send the schedule or next job data down to the control. It is a semicolon delimited string and takes on the form: String
ID;Next Tool Number;Next PRESET;Next Job String;Next Part String1, Next Part String2…Next Part String 5 Here’s an example of
such a string: “1; 1234; 100000; J5678; P1000, P2000, P3000”. If there is no schedule then this is indicated by the following string:
“1;;;;”
EXPANDED - Start Time amd Angle Tags
Resolver angle* 400019 Word

* Due to the latency of the information, the Resolver Angle tag should not be used for control purposes.
Start time 400022 Word
Start time limit 400042 Word
EXPANDED - I/O Status Tags
DipPro Sensor Enable Status (0=Enabled, 1=Disabled) 400514 Word

Dipro input status (DiproPac req'd, up to 16 inputs only) 400072 Word
The DiPro input status tag's 16 bits indicates which sensors (1-16) are actuated (0=off, 1=actuated).
Procam output status (ProCamPAC Req'd) 400073 Word
The ProCam ouput status tag's 16 bits indicates which ProCam channels (1-16) are on (0=off, 1=on).
WPC input status (WPC req'd) 400074 Word
Bit 0=Off Mode, Bit 1 = Inch Mode, Bit 2 = Single Stroke Mode, Bit 3 = Continuous Mode, Bit 4 = Operator Station 1 Input On, Bit
5 = Operator Station 2 Input On, Bit 6 = WPC Lockout Input On, Bit 7 = Remote “RESET” On
Input check input status (0-Off, 1-On) 400075 Word

Actual Flywheel Speed (Requires WPC 2000 with flywheel sensor) 400055 Word
Motor Slowdown Percentage (Requires WaveFormPAC Module) 400059 Word
Current Command Speed (*Requires WPC 2000 w/option 2) 400056 Word

EXPANDED - RamPAC Tags RamPAC Module Req'd
RamPAC Counterbalance actual 400045 Word

RamPAC Counterbalance setpoint 400046 Word
RamPAC Cushion actual 400047 Word
RamPAC Cushion setpoint 400048 Word
RamPAC units 400049 Word
RamPAC shutheight actual 400453 Dword
RamPAC shutheight setpoint 400455 Dword
EXPANDED - AutoSetPAC Tags AutoSetPAC or WaveformPAC Module Req'd
Input 1 forward tonnage 400257 Word

Input 1 reverse tonnage 400269 Word
Input 1 high setpoint 400273 Word
Input 1 low setpoint 400277 Word
Input 1 rep setpoint 400281 Word
High setpoint % 400310 Word
Low setpoint % 400311 Word
Rep setpoint % 400313 Word
Startup counter 400319 Word
Sample period 400320 Word
Inputs 1 - 4 total forward load 400321 Word
Inputs 1 - 4 total high setpoints 400341 Word
Inputs 1 - 4 total low setpoints 400346 Word
Inputs 1 - 4 total rep setpoints 400351 Word

Table 3: SmartPAC PRO/ WPC2000 Series Modbus Registers
MODBUS
Tag Value
Tag Name/Description Register
Length Range
Number
Counters_Strokes_Count
402001 DWord 0-16,777,216
(32-bit)
Counters_Strokes_PRESET
402003 DWord 0-16,777,216
(32-bit)
Counters_GoodParts_Count
402005 DWord 0-16,777,216
(32-bit)
Counters_GoodParts_PRESET
402007 DWord 0-16,777,216
(32-bit)
Counters_Non_”RESET”able_Strokes_Count
402009 DWord 0-16,777,216
(32-bit)
Counters_Non_”RESET”able_GoodParts_Count
402011 DWord 0-16,777,216
(32-bit)
Counters_Non_”RESET”able_Scrap_Count DWord
402013 0-16,777,216
(32-bit)
Press_ShaftAngle Word
402015 0-9,999
(16-bit)
Press_ShaftRPMProductionRate Word
402016 0-9,999
(16-bit)
DiProPAC_StatusBits_Input Word
402017 0-9,999
(16-bit)
ProCamPAC_StatusBits_Output Word
402018 0-9,999
(16-bit)
Rts_MachineStatus Word
402019 0-9,999
(16-bit)
Rts_MachineStateReason Word
402020 0-9,999
(16-bit)
Rts_InputCheckStatus Word
402021 0-9,999
(16-bit)
Rts_ModeSelectorInputStatus Word
402022 0-9,999
(16-bit)
RamPAC_CounterBalance_Actual Word
402023 0-9,999
(16-bit)
RamPAC_CounterBalance_SetPoint Word
402024 0-9,999
(16-bit)
RamPAC_Cushion_Actual Word
402025 0-9,999
(16-bit)
RamPAC_Cushion_SetPoint Word
402026 0-9,999
(16-bit)
RamPAC_ShutHeight_Actual DWord
402027 1-9,999,999
(32-bit)
RamPAC_ShutHeight_SetPoint DWord
402029 1-9,999,999
(32-bit)
RamPAC_ShutHeight_Units Word
402031 0-9,999
(16-bit)
TonnageMonitor_TotalForwardLoad Word
402032 0-9,999
(16-bit)
Press_StopTime_Actual Word
402033 0-9,999
(16-bit)
Press_StopTime_Limit Word
402034 0-9,999
(16-bit)

MODBUS
Tag Value
Length Range
Number
Press_StartTime_Actual Word
402035 0-9,999
(16-bit)
Press_StartTime_Limit Word
402036 0-9,999
(16-bit)
Production_Operator_Number0 DWord
402037 1-9,999,999
(32-bit)
Production_ToolString_Current 402039.16L String (16 Char Max)
Production_JobString_Current 402047.14L String (14 Char Max)
Production_PartString_Current 402055.26L String (26 Char Max)
Rts_Machine_State Word
Rts Machine State 0=Off, 1=Run, 4=Unplan, 5=Chg, 6=Idle, 7=Plan 402077 0-9,999
(16-bit)
Rts_Machine_Reason Word
402078 0-9,999
(16-bit)
Rts_OperatingMode Word
Rts Operating Mode (0=Prog, 1=Run, 2=Init) 402079 0-9,999
(16-bit)
Counters_Batch1_Count
402080 DWord 0-16,777,216
(32-bit)
Counters_Batch1_PRESET
402082 DWord 0-16,777,216
(32-bit)
402084 DWord 0-16,777,216
(32-bit)
402086 DWord 0-16,777,216
(32-bit)
402088 DWord 0-16,777,216
(32-bit)
402090 DWord 0-16,777,216
(32-bit)
Counters_TotalHits_Count
402092 DWord 0-16,777,216
(32-bit)
Counters_TotalHits_PRESET DWord
402094 0-16,777,216
(32-bit)
RamPAC_Bruderer_Feedlength_Setpoint DWord
402096 1-9,999,999
(32-bit)
RamPAC_Bruderer_Stroke_Length DWord
402098 1-9,999,999
(32-bit)
System_Info_SerialNumber DWord
402100 1-9,999,999
(32-bit)
System_Info_Versions_RTS Word
402102 0-9,999
(16-bit)
System_Info_Versions_Main Word
402103 0-9,999
(16-bit)
Press_CurrentCommandSpeed Word
402104 0-9,999
(16-bit)
Press_Speed_Min Word
402105 0-9,999
(16-bit)
Press_Speed_Max Word
402106 0-9,999
(16-bit)
TonnageMonitor_Press_Capacity Word
402107 0-9,999
(16-bit)
TonnageMonitor_StartupCounter Word
402108 0-9,999
(16-bit)

MODBUS
Tag Value
Length Range
Number
TonnageMonitor_SamplePeriod Word
402109 0-9,999
(16-bit)
TonnageMonitor_Input1_ForwardTonnage Word
402110 0-9,999
(16-bit)
402111 0-9,999
(16-bit)
402112 0-9,999
(16-bit)
402113 0-9,999
(16-bit)
TonnageMonitor_Input1_ReverseTonnage Word
402114 0-9,999
(16-bit)
402115 0-9,999
(16-bit)
402116 0-9,999
(16-bit)
402117 0-9,999
(16-bit)
TonnageMonitor_Percentage_HighSetPoint Word
402118 0-9,999
(16-bit)
TonnageMonitor_Percentage_LowSetPoint Word
402119 0-9,999
(16-bit)
TonnageMonitor_Percentage_RepSetPoint Word
402120 0-9,999
(16-bit)
TonnageMonitor_TotalHighSetPoints_Inputs1Thru4 Word
402121 0-9,999
(16-bit)
TonnageMonitor_TotalLowSetPoints_Inputs1Thru4 Word
402122 0-9,999
(16-bit)
TonnageMonitor_TotalRepSetPoints_Inputs1Thru4 Word
402123 0-9,999
(16-bit)
TonnageMonitor_Input1_HighSetPoint Word
402124 0-9,999
(16-bit)
402125 0-9,999
(16-bit)
402126 0-9,999
(16-bit)
402127 0-9,999
(16-bit)
TonnageMonitor_Input1_LowSetPoint Word
402128 0-9,999
(16-bit)
402129 0-9,999
(16-bit)
402130 0-9,999
(16-bit)
402131 0-9,999
(16-bit)
TonnageMonitor_Input1_RepSetPoint Word
402132 0-9,999
(16-bit)
402133 0-9,999
(16-bit)
402134 0-9,999
(16-bit)
402135 0-9,999
(16-bit)

MODBUS
Tag Value
Length Range
Number
Bruderer_CurrSelectedRunSpeed Word
402195 0-9,999
(16-bit)
Bruderer_CurrLoadedInchSpeed Word
Bruderer Currently Loaded Inch Speed 402196 0-9,999
(16-bit)
Bruderer_CurrLoadedSingleStrokeSpeed Word
Bruderer Currently Loaded Single Stroke Speed 402197 0-9,999
(16-bit)
Bruderer_CurrLoadedContStartSpeed Word
Bruderer Currently Loaded Continuous Start Speed 402198 0-9,999
(16-bit)
Bruderer_CurrLoadedContRunSpeed Word
Bruderer Currently Loaded Continuous Run Speed 402199 0-9,999
(16-bit)
Production_Write W402201.200L String (200 Char Max)
WPC_Mode_Bits Word
402301 0-9,999
(16-bit)
WPC_OpStation_Bits Word
402302 0-9,999
(16-bit)
WPC_Status_Bits Word
402303 0-9,999
(16-bit)
WPC Zero Corrected Angle Word
402304 0-9,999
(16-bit)
WPC_PressOrFlywheelSpeed Word
402305 0-9,999
(16-bit)
WPC_SpacCurrErrNum Word
WPC Spac Current Error Number 402306 0-9,999
(16-bit)
RemoteMouseDetected Word
402307 0-9,999
(16-bit)
RTS_CurrHelpScreenNumber Word
Gives indication of screen SPRO is on 402308 0-9,999
(16-bit)
Client_KeepAlive Word
402309 0-9,999
(16-bit)
RTS_CurrLanguage
English=0, Spanish=1, Portuguese=2, German=3, Russian=4, Chinese=5, Polish=6 Word
402310 0-9,999
(16-bit)
The following tags only apply if PLC Ethernet Option is present:

PLC_Tool_Long00 DWord
402311 1-9,999,999
(32-bit)
402313 1-9,999,999
(32-bit)
402315 1-9,999,999
(32-bit)
402317 1-9,999,999
(32-bit)
402319 1-9,999,999
(32-bit)
402321 1-9,999,999
(32-bit)
402323 1-9,999,999
(32-bit)
402325 1-9,999,999
(32-bit)
402327 1-9,999,999
(32-bit)
402329 1-9,999,999
(32-bit)

MODBUS
Tag Value
Length Range
Number
Contains the numeric Tool Number 402331 1-9,999,999
(32-bit)
402333 1-9,999,999
(32-bit)
402335 1-9,999,999
(32-bit)
402337 1-9,999,999
(32-bit)
402339 1-9,999,999
(32-bit)
402341 1-9,999,999
(32-bit)
PLC_Tool_Float00 402343 Float
PLC_Status_Msg W402401.100L String (100 Char Max)

Reporting Downtime and Scrap from SmartPAC

This section explains how to create and assign downtime reason codes at your SmartPAC
and describes how to use the SmartPAC Dialog Menu to send the downtime reasons back to
your software. The document also explains how to adjust the Good Parts and Scrap parts
counts that SmartPAC reports back to your software.
SmartPAC’s downtime and scrap reporting features are available only on SmartPAC 2,
versions 4.59 or higher, and SmartPAC PRO; in addition, the Enhanced 3rd-Party
Communications firmware option must be installed.
SmartPAC Machine States (Modbus Register 401022)

Every time the SmartPAC is polled, it reports the machine status as 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.).
SmartPAC selects the machine state based on whether the machine is running and the
currently selected downtime reason (if any). Machine states are 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 (in other words, the operator has
not yet selected a downtime reason from the Dialog Menu).
• Unplanned Downtime - Press is stopped due to a SmartPAC error, or if the press is
stopped for another reason, the press operator has selected a downtime reason other
than Planned Downtime or Tool Change
• Planned Downtime - Press is stopped, and the press operator has selected Planned
Downtime from the Dialog Menu as the reason.
• Changeover Time - Press is stopped, and the press operator has selected Tool Change
from the Dialog Menu as the reason.
• Offline Time - Press is stopped because there is no power to the press or the
network is down.
Whenever the press is stopped for any reason other than a power interruption or network
failure, the machine state will be Idle Time - unless the SmartPAC is displaying an error, or a
downtime reason was selected from the SmartPAC Dialog Menu by the press operator.
While it is helpful to know that a press was stopped, it is infinitely more valuable to know why
it was stopped. To help you to collect the actual reasons for downtime, the SmartPAC may be
programmed so that it requires the operator to select a specific downtime reason any time
the press persists in the Idle state for longer than a preset time period.

SmartPAC Downtime Reporting Features

Downtime reasons in SmartPAC may be reported either automatically by the system or
manually by the operator. When the press is stopped because of an error generated by
SmartPAC or an installed SmartPAC module, the specific fault (e.g., “Sensor 1 Part Ejection
Missed”) is reported automatically as an unplanned downtime reason.
When the press is stopped by the operator or by a piece of auxiliary equipment not
connected to the SmartPAC, a downtime reason must be reported manually by the
operator since SmartPAC is unable to detect the reason for the interruption. Downtime
reasons may also be assigned manually in order for the operator to provide additional
detail for periods documented automatically with specific error conditions (see Forced
Error Dialog Mode, page 17).
State and Reason Tag behavior

If the SmartPAC stops the press, it will set the State Tag (Modbus Register 401022) to a
value of “4” (Unplanned Downtime), and the Reason Tag (Modbus Register 404023) to the
value in the Error Lookup Table (see Table 6 on Pages 31-43) that corresponds to the
specific error generated by the SmartPAC.
If the press is stopped by the operator or by a piece of auxiliary equipment, the SmartPAC
immediately sets the State Tag (Modbus Register 401022) to a value of “6” (Idle), and the
Reason Tag (Modbus Register 404023) to the value of “0”.
Any time after the machine is stopped, the operator may specify the reason for the
stoppage by selecting “DIALOG MENU” from the SmartPAC’s main run menu. The Dialog
Menu is the list of downtime reasons configured for the machine (see page 16). The state
and reason code will change immediately when the operator selects the downtime reason
(see the Table 3 on Page 9).
If the press is restarted while in the Idle state before the operator specifies a downtime
reason, the true reason for the stoppage will not be reported. However, the SmartPAC has
a feature called the “Forced Idle Dialog Mode” that, when enabled, gives you the
opportunity to capture the “real” reason for downtime during an “Idle” event.
Forced Idle Dialog Mode

If the SmartPAC’s Forced Idle Dialog mode is enabled (see Setting up SmartPAC to Report
Downtime on page 19), the SmartPAC will inhibit further machine operation until the
operator specifies a downtime reason after a significant period of Idle time. In other
words, a downtime reason must be entered when the press is stopped for longer than a
preset period of time for any reason other than a SmartPAC error. The preset time period is
called the “Idle Dialog Time”. The Idle Dialog Time allows the press to be stopped briefly
and restarted without requiring entry of a downtime reason.

When the press is stopped for a period of time long enough to allow the Forced Dialog Timer to
time out, the SmartPAC opens its e-stop relays and a message displays on the SmartPAC
stating that the operator must select a downtime reason before the press can be restarted.
When the operator closes the message window, a menu called the Dialog Menu
automatically displays.
The Dialog Menu is the list of downtime reasons available on the press (Refer to
Programming Downtime Reasons, page 21 for instructions on how to create the Dialog
Menu.). In order to close the e-stop relays and allow the press to run, the operator must
select a reason from this list which will insert a 3-digit downtime code into Modbus
Register 401023.
Table 4 - Downtime State and Reason Code Table
State Tag Value Reason Tag Value

Reason Description Modbus Register Modbus Register
401023 401023
Coil change 4 221
Tool change 5 222
Bin full 4 223
Forklift 4 224
Quality control 4 225
User-definable reason #1 4 227
Lube problem 4 232
Air problem 4 233
Electrical problem 4 234
Mechanical problem 4 235
Part ejection 4 237
Planned downtime 7 238
Part quality 4 239

In order to take advantage of the Forced Dialog Mode and capture the real downtime
reason for significant Idle events, you will need to configure your software to detect when
the State and Reason values (Modbus Registers 401022 and 401023) switch from 6 and 0 to
either 4, 5, or 7, and a 3-digit downtime code; then “backfill” the preceding period of Idle
time with the new state and reason.
Putting the Press “Back on Line”

A period of Idle Time or downtime (either “Planned” or “Unplanned”) comes to an end
when the operator either restarts the machine (see Error Reset Strokes Counter on page
18), or selects “Back on line” from the Dialog Menu. When the press is restarted, a State
Code of 1 (Running) will be reported in Modbus Register 401022. If the operator selects
“Back on Line” without restarting the press, a State Code of 6 (Idle) will be reported in
Modbus Register 401022 until the press is restarted.
Forced Error Dialog Mode

You can also configure SmartPAC to require the operator to manually select a
downtime reason when a SmartPAC error message persists for an extended period of
time. This feature, called Forced Error Dialog mode (see Making Downtime
Reporting Settings, page 19), allows the operator to add detail to a period of
downtime that is initially logged to a specific SmartPAC error but may actually have a
different cause.
For example, say a SmartPAC has a die protection sensor that generates an “End of
Stock” error whenever the press runs out of material, and that one day this sensor
stops the press while the operator is otherwise occupied, and the machine sits with
that error on the screen for 45 minutes before the operator is able attend to the
machine and restart it. This event would result in 45 minutes of downtime being
attributed to “End of Stock”, while the real reason for downtime might be more
accurately described as “Operator Busy”.
As with the Forced Idle Dialog mode, the Forced Error Dialog message can be
programmed to appear a specified number of minutes after the press stops. This
time period is specified by the Error Dialog Time setting.
Persist Dialog Mode

When enabled, the Persist Dialog Mode causes the SmartPAC to remember the downtime
reason while it is powered off and reinstate the reason when the power comes back on
again. If the Persist Dialog Mode is disabled, the press will power up in the Idle state
regardless of which state the machine was in when it powered off.

Single-Stroke Mode and Idle Timer

Normally, the SmartPAC updates the state, (401022), reason (401022), and speed (401016)
tags immediately, in real time. This is effective when running the press in the continuous
mode but is troublesome if you run hand-fed operations in the single stroke mode.
When single stroking the machine, the state (404022) value will be constantly alternating
between “Running” (1) and “Idle” (6) because of the brief stoppages while the part is being
placed in the die.
Also, rather than getting an indication of the actual production rate, the speed will be reported
as either “0” if the Modbus tag is updated between strokes, or as the actual resolver speed if it
is updated while the ram is moving – neither is really accurate.
The SmartPAC has a setting called the Single Stroke Mode, that when enabled works in
conjunction with another setting called the “IDLE TIMER” to decide when to switch the
machine state from running (Modbus register 401022 value of “1”) to Idle (Modbus register
401022 value of “6”). When the machine stops, the SmartPAC will hold the Running state
for the time period specified by the IDLE TIMER. If the machine is cycled again during that
time, the state will remain as Running. If the machine does not cycle by the end of the IDLE
TIMER, SmartPAC will change the machine state to Idle.
In addition, the SmartPAC will calculate a production rate in strokes per minute rather than
reporting the instantaneous resolver speed on Modbus Register 401016.
Error “RESET” Strokes Counters

There are two ways for a press operator to take a SmartPAC out of the Planned Downtime,
Unplanned Downtime, or Changeover state:
1. Select “Back on Line” from the Dialog menu, which changes the state to Idle.
2. Start the machine, which will automatically change the state to Running.
If the machine state is Idle or Planned Downtime, it is desirable to switch the machine state
to Running immediately when the press is restarted. However, this is not the case when
the machine is in Unplanned Downtime state or Changeover because it might be necessary
to cycle the machine while loading a new coil or changing dies, and it is preferable for the
SmartPAC to “hold” the state long enough for the coil change or changeover to be
completed.
The Reset Strokes Counters in SmartPAC enable the SmartPAC to hold each state for the
specified number of strokes after the machine has been started. There are separate
counters that control this behavior when the SmartPAC is coming out of the Planned
Downtime, Unplanned Downtime, and Changeover states.
For example, if your operators normally cycle the press 10 times during a coil change, you
would set the Unplanned Downtime reset Strokes Counter to 10. Then whenever an
operator selects “Coil Change” (or any other unplanned downtime reason) the SmartPAC
will hold that state and reason for 10 strokes after the machine starts up. On the 11th
stroke, it will switch the state from Unplanned Downtime to Running.

Setting up SmartPAC to Report Downtime

To set up SmartPAC to report downtime, you first configure the reporting settings on the
Set Communications Menu, and then program the downtime reasons on the Dialog Fixed
Name Choice Menu and the Dialog Special Choice Name Menu.
Making Downtime Reporting Settings

To enable and configure the SmartPAC downtime reporting features described in the
previous section, perform the following steps:
1. Turn the SmartPAC’s Program/Run key to “PROG” then press the “1” and “CLEAR” keys
simultaneously for a second or two until the Main Initialization Menu appears or press
the “Initialization Menu” item on the SmartPAC PRO.
2. Highlight the “SETUP DATA COMMS” menu item, using the Up or Down cursor key,
and press “ENTER”. The Set Communications Menu (see Figure 1-2) displays.
Figure 1-2 - Set Communications Menu
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 (except IDLE TIMER), press “ENTER” to display the
Numeric Entry window, key in your entry then press “ENTER” again.
• 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.

The table below explains each field on the Set Communications Menu and provides
instructions on how to make settings.
Table 5 – SET DATA COMMS Settings
Field Settings
RSR/SBR CPU NUMBER This field must be set to “1.”
FORCED IDLE DIALOG Indicates whether SmartPAC 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. 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. 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.
FORCED ERROR DIALOG Indicates whether SmartPAC displays the Forced Dialog message
and Dialog Menu after the press has been stopped by a SmartPAC
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.
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
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 after the press is powered up again. There are two settings:
ENABLED Persist Dialog mode enabled
DISABLED Persist Dialog mode disabled
AUTO BACKFILL This MUST be Set to DISABLED
DIALOG SCREEN MODE This MUST be set to 16/16.

Table 5 - Set Communications Menu Settings (Cont)
Field Settings
UNPLANNED “RESET” STROKES Specifies the number of strokes that must occur after the press is
restarted following a period of Unplanned Downtime, Planned
PLANNED “RESET”
STROKES Downtime, or Changeover Time before SmartPAC changes the
machine state to “Running.”
CHANGEOVER “RESET”
STROKES
SINGLE STROKE MODE Used when the press is being run in Single-stroke mode, it
determines whether the SmartPAC changes the state from Running
to Idle immediately upon stoppage, or if it waits for the IDLE TIMER
to time out. When enabled, the SmartPAC will report a calculated
speed value rather than the instantaneous value.
ENABLED Single-stroke Mode enabled
DISABLED Single-stroke Mode disabled
IDLE TIMER The IDLE TIMER set the amount of time after a stoppage is detected
that that the SMARTPAC will hold the Running state before switching
to Idle. It also specifies the number of seconds during which
SmartPAC counts the number of press strokes in Single-stroke
mode to determine a production rate for hand-fed applications.
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 24).
If you do not see this menu choice, verify that the DIALOG SCREEN
MODE is set to 16/16.
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 22).
If you do not see this menu choice, verify that the DIALOG SCREEN
MODE is set to 16/16.
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. “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 SmartPACs
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 top of the Dialog Menu.
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 1-3) appears. 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. You can select up to
14 of these pre-programmed entries for inclusion in the Dialog Menu.
Figure 1-3 - 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 1-3, 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

gaps in your “canned” name numbering scheme to accommodate these items.

To prevent an item from showing 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
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
cursor keys, and press “ENTER”. The Dialog Fixed Name Choice Menu (see Figure 1-3)
appears 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
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 1-4) appears. 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 1-4 - 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 and press
“ENTER”. The Dialog Special Choice Name Menu (see Figure 1-4) 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.
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
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 SmartPAC
Downtime Reporting Features, page 15), the operator is prompted to enter a downtime
reason on the Dialog Menu whenever SmartPAC detects that the press has stopped under
the appropriate circumstances. This message is shown in Figure 1-5.
F8
Figure 1-5 - SmartPAC 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.
F8
Figure 1-6 - Dialog Menu
2. Highlight the downtime reason you want (in Figure 1-6, MECH PROBLEM is selected as an
example) using the cursor keys, and press “ENTER”. The SmartPAC will display a message
stating that the downtime reason has been sent to the host computer.
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, select the DIALOG MENU item.
2. On the Dialog Menu, highlight the downtime reason you want, and press “ENTER”. A
window appears with instructions for keeping or changing the downtime reason. This
functionality is included in the 3rd Party Communications firmware to maintain
compatibility with existing legacy products and is no longer used.
3. To continue, press either “F2” or “F3” to change the downtime reason, as both choices
produce the same result.

How SmartPAC Reports the Strokes, Good Parts, and Scrap Parts
Counters
There are three data tag values that you can use to track various counts from the SmartPAC:
MODBUS Register 401009 contains a non-resettable “free-running” Stroke counter that

increments by 1 every time the press makes a cycle. The range of values is from 0 to
16,777,216. When the maximum value is reached, the counter rolls over, resets to zero, and
begins counting up again. There is no way to manually reduce this counter. It will only
increment.
MODBUS Register 40101 contains a non-resettable “free-running” Good Parts counter. The
range of values is from 0 to 16,777,216. When the maximum value is reached, the counter
rolls over, resets to zero, and begins counting up again. The Good Parts counter increments
when the following three conditions are met:
1. The SmartPAC is NOT in the Setup Mode.
2. The machine makes a complete cycle.
3. The SmartPAC does not go into any kind of fault condition (such as a die protection or
tonnage monitor fault) during the cycle.
Like the Non-resettable Stroke Counter, there is no way to manually reduce this counter. It
can only be incremented.
MODBUS Register 401021 contains a non-resettable “free-running” Scrap Part counter that
increments when the operator manually adds to the SmartPAC scrap counter (see
description on page 22). Like the other two counters, the range of values is from 0 to
16,777,216. When the maximum value is reached, the counter rolls over, resets to zero, and
begins counting up again. There is no way to manually reduce this counter. It will only
increment.
Using the Counters in SmartPAC

To enable scrap entries and Good Parts counter adjustment in the Run mode, you must set
the CHANGE COUNTS and CHG GOOD PRTS CNT items on the Security Access Menu in
Initialization mode to “PROGRAM AND RUN MODES,” as shown in Figure 1-7. (To display the
Security Access Menu, select “SECURITY ACCESS” from the Main Initialization Menu.)
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 COUNTS item set to “PROGRAM AND
RUN MODES.”

F8
Figure 1-7 - Security Access Menu with CHANGE COUNTS and CHG GOOD PARTS 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 in SmartPAC Initialization to “INC ALWAYS.”
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 to
display the Counters screen
2. Press “F3” (Scrap Value). The Scrap Value Entry window displays (see Figure 1-8).
F8
Figure 1-8 - Counters Screen with Scrap Value Entry Window Displayed (30 Items Shown)

3. Enter the number of scrap parts you wish to record, following the directions in the window,
and press “ENTER”. (Figure 1-9 shows a scrap entry of “30” as an example.) When you
press “ENTER”, the value in MODBUS Register 401021 will increment by the value you
entered. In the example above, 30 counts will be added to the Non-resettable Scrap
Counter.
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 1-9, where a scrap value of “30” is used as an example.
This value represents the running total of scrap parts counted so far for this job. It will
reset to 0 when a new job is loaded.
F8
Figure 1-9 - Counters Screen with Scrap Value Updated to 30 Items

Even though the Good Parts counter displayed on the SmartPAC is reduced by the
amount of your scrap entry (e.g., 900-30=870 in Figure 1-9), this entry has no effect on
the non-resettable Good Parts Counter in MODBUS register 401011.
4. If you have made previous Scrap Value entries for this job, the value shown under the
words SCRAP VALUE in the label for function key “F3” will display the running total of all
of the scrap parts for the current job.
Adjusting the Good Parts Counter
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.
Any adjustments made to the Good Parts Counter will be immediately added to the Non-
resettable Good Parts Count held in MODBUS Register 401011.
Adjusting the Good Parts Counter in Run Mode at the SmartPAC

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 1-10) displays, enter
the number of good parts you want to add (1,000 parts maximum), and press “ENTER”.
Figure 1-10 - Good Parts Counter Adjustment Confirmation Window
3. Press the Up Arrow 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.
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.

Table 6 - Error Lookup Table

Error Code Error Description
8 E-stop driver failure
12 Position sensor incorrect
13 System failure (program memory checksums incorrect)
14 Angle resolver problems (both drive and stator)
17 Input module failure
19 Module WPC, SFI, STI, or PLC communications error
23 Stop time exceeded (upstroke or down stroke)
24 Loss of rotation
25 Setup table checksum incorrect or no setup loaded
26 Maximum or minimum speed exceeded
31 Stroke counter preset reached
32 Good parts counter preset reached
33 Batch counter preset (1-3) reached
34 Host-computer-generated top-stop
35 MultiPAC fault
36 RamPAC fault
37 Lube fault
38 Hydraulic overload 1 fault
39 Hydraulic overload 2 fault
40 Lube switch 1 fault
41 Lube switch 2 fault
42 Sump return fault
43 Outer right-hand bearing fault
44 Inner right-hand bearing fault
45 Right-hand center bearing fault
46 Right-hand connection bearing fault
47 Left-hand connection bearing fault
48 Left-hand center bearing fault
49 Inner left-hand bearing fault
50 Outer left-hand bearing fault
51 High setpoint exceeded on channel 1
59 Tool ID tool number mismatch

Table 6 - Error Lookup Table (cont.)

61 Low setpoint exceeded on channel 1
71 Repeatability setpoint exceeded on channel 1
49 Inner left-hand bearing fault
50 Outer left-hand bearing fault
59 Tool ID tool number mismatch


81 Reverse setpoint exceeded on channel 1
91 120% press capacity exceeded on channel 1
101 Zero offset exceeded on channel 1
114 Yellow sensor “on” sensor 1


131 Red sensor “off” sensor 1
148 Green Quick Check sensor “on” outside Ready signal sensor 1
165 Green sensor missed sensor 1


182 Green sensor failure sensor 1
199 Green sensor late sensor 1


221 Coil change
222 Tool change
223 Bin full
224 Forklift
225 Quality control
227 User-definable downtime reason #1 (see document #1137900)
232 Lube problem
233 Air problem
234 Electrical problem
235 Mechanical problem
237 Part ejection
238 Planned downtime
239 Part quality
253 Green Constant sensor “off” in Ready signal sensor 1


269 Green Special sensor missed sensor 1
302 F02 Press was started in Continuous mode with the Shadow bypass switch (mute limit
switch input #26) “on”
303 F03 Bottom dwell loss of rotation input (mute limit switch input #26) closed at start of
stroke
304 F04 Resolver drive signal level incorrect
305 F05 Sum of resolver stator signals incorrect
306 E06 Resolver was turning too fast, or the R/D converter system failed
307 E07 Resolver tried to zero outside of 330 to 30 degree range
310 F10 Main motor is off without Two-hand Inch operating mode selected


311 F11 Uncommanded motion occurred
313 F13 E-stop button pressed or E-stop circuit open
314 F14 Prior Act button pressed at start of stroke
315 F15 Counter preset reached
316 F16 Top-stop button pressed or Top-stop circuit open at start of stroke
317 F17 User input 8/9 pair disagree
318 F18 User input 10/11 pair disagree
319 F19 Auxiliary E-stop relay not open before being turned “on”
320 F20 Main motor is in reverse without Two-hand Inch operating mode selected
321 F21 Operator station logic incorrect
322 F22 Operating mode was changed while press was running
323 F23 Operating mode selected is not a valid mode
324 F24 Both palm buttons were pressed while in One-hand mode, or the N/O palm
button inputs from an unselected operator station were closed
325 F25 Flywheel speed sensor not turning “on” and “off” properly when spin-down is
enabled
326 F26 Ram was moved too fast in Bar mode
327 F27 Press speed exceeded the maximum press speed setpoint
328 F28 Main motor was reversed before spin-down timer ran out
329 F29 Flywheel speed sensor is turning “on” and “off” with spin-down disabled
330 F30 A and B processor resolver angles disagreed by more than 2 degrees
331 F31 No reply received from B processor to Check Start request
333 F33 Incorrect reply received from B processor to Mode Change message
334 F34 No reply received from B processor to Mode Change message
335 F35 Incorrect reply received from B processor to Power-up message
336 F36 No reply received from B processor to “RESET” Error message
337 F37 No reply received from B processor to Compare Input Buffers message
340 F40 Ram was not in proper position for adjustment, the press needs to be near TDC
341 F41 Input buffer 1 check incorrect
345 F45 Transducer-measured main system air pressure was below the setpoint
346 F46 Transducer-measured counterbalance air pressure was outside the pressure limits
347 F47 DSV monitor switch input open
348 F48 Main system air pressure switch input open
349 F49 User input 11 open


360 F60 Light curtain A inputs did not open during light curtain test
361 F61 Light curtain B inputs did not open during light curtain test
362 F62 Light curtain B inputs are closed with only light curtain A mode selected
363 F63 Light curtain A inputs are open at start of or during stroke
364 F64 Light curtain B inputs are open at start of or during stroke, or dual light curtains are
selected with only one set connected
365 F65 Light curtains connected with Two-hand Only firmware installed
366 F66 E-stop circuit did not open during E-stop circuit test
367 F67 Top-stop circuit did not open during Top-stop circuit test
368 F68 Light curtain A inputs disagree
369 F69 Light curtain B inputs disagree
370 F70 DSV A relay not open at start of stroke
371 F71 DSV A driver did not turn “on” or DSV B was not “off” during pulse in 10
millisecond window test.
372 F72 DSV A Control Flip-flop not functioning properly
373 F73 DSV A Missing Pulse Detector window not functioning properly
374 F74 DSV A relay did not close properly at start of stroke
375 F75 DSV A relay did not open properly at end of stroke
376 F76 Lockout relay driver did not turn “off” properly during test
377 F77 Lockout relay check contacts were not closed before the lockout relay was turned
“on”
378 F78 Position of DSV poppets is incorrect (Minster version)
379 F79 Loss of rotation
380 F80 Press was still muted when Overrun switch closed
381 F81 More than one limit switch was closed at one time
382 F82 Press was still muted when Carry-up limit switch closed
383 F83 Mute limit switch did not close or was out of sequence
384 F84 Carry-up limit switch did not close or was out of sequence
385 F85 Overrun switch closed without seeing the other three limit switches (i.e., closed more
than once)
386 F86 Too many limit switch set flags are set


387 F87 Top-stop limit switch did not close or was out of sequence
388 F88 Overrun limit switch did not close or was out of sequence
389 F89 Overrun limit switch was not closed at overrun test angle, or Overrun limit
switch was not open at 180 degrees
390 F90 Program memory checksum 1 incorrect
391 F91 Program memory checksum 2 incorrect
395 F95 Angle table memory checksum incorrect
396 F96 RAM memory failed memory test
397 F97 No angle setup loaded
398 F98 Option switch image changed during operation
399 F99 + 24 Vdc failed or the fuse blew
400 F100 Stop time exceeded
401 F101 Interrupted Stroke mode
402 F102 Lockout mode
403 F103 Control Off mode
404 F104 Operating mode is not defined
405 F105 Motor Is Off mode
406 F106 Motor Is in Reverse mode
407 F107 Motor shut-down timer turned motor off


440 F140 User input 32 or 33 open
444 F144 User input 32 and 33 disagree
454 H04 Resolver drive signal level incorrect
455 H05 Sum of resolver stator signals incorrect
510 H60 Light curtain A inputs did not open during light curtain test
511 H61 Light curtain B inputs did not open during light curtain test
516 H66 E-stop circuit did not open during E-stop circuit test
517 H67 Top-stop circuit did not open during the Top-stop circuit test
522 H72 DSV A Control Flip-flop not functioning properly
523 H73 DSV A Missing Pulse Detector window not functioning properly
524 H74 DSV A relay did not close properly at start of stroke
525 H75 DSV A relay did not open properly at end of stroke
526 H76 Lockout relay driver did not turn “off” properly during test
529 H79 Loss of rotation
530 H80 Press was still muted when Overrun switch closed
531 H81 More that one limit switch was closed at one time
532 H82 Press was still muted when Carry-up limit switch closed
533 H83 Mute limit switch did not close or was out of sequence
534 H84 Carry-up limit switch did not close or was out of sequence
535 H85 Overrun switch closed without seeing other three limit switches (i.e., closed more
than once)
536 H86 Too many limit switch set flags are set
537 H87 Top-stop limit switch did not close or was out of sequence
538 H88 Overrun limit switch did not close or was out of sequence
539 H89 Overrun limit switch was not closed at overrun test angle, or Overrun limit
switch was not open at 180 degrees
540 H90 Program memory checksum 1 incorrect
541 H91 Program memory checksum 2 incorrect
545 H95 Angle table memory checksum incorrect
546 H96 RAM memory failed memory test
570 F150 Main lube fault cycle switch
571 F151 Lube cycle switch 1 fault


572 F152 Lube cycle switch 2 fault
573 F153 Hydraulic overload fault after BDC
574 F154 Hydraulic overload fault before BDC
575 F155 Hydraulic overload not pressurized at top
576 F156 Flywheel brake fault
577 F157 CAN communications failure
578 F158 4-20 mA speed input loop failure
579 F159 Processor A and B option board type disagreement
580 F160 Unsupported option board type was installed
581 F161 Hydraulic overload switch is closed with pump not “on”
582 F162 Lube motor “off” with main motor turned “on”
600 Undefined RamPAC error
601 Shut height not correct
602 Counterbalance parameters have been corrupted
603 Shut height parameters are not correct
604 Shut height outside upper/lower limit
605 Counterbalance pressure different from setpoint
606 Counterbalance pressure below minimum value
607 Position transducer did not indicate ram was moving
608 Shut height control in manual mode
609 Cushion pressure different from setpoint
610 RamPAC control has “RESET” due to a noise disturbance
611 RamPAC did not receive a zero signal from SmartPAC
612 RamPAC did not receive an Input Check signal
613 Shut height cannot be adjusted at press angle
619 Ram depth control not in auto mode when loading new tool
825 to 840 ProPAC1 High setpoint exceeded sensor 1 to 16
841 to 856 ProPAC1 Low setpoint exceeded sensor 1 to 16
857 to 872 ProPAC1 Yellow sensor closed sensor 1 to 16
873 to 888 ProPAC1 Red sensor open sensor 1 to 16
889 to 904 ProPAC1 Green Quick Check sensor “on” outside Ready signal sensor 1 to 16
905 to 920 ProPAC1 Green sensor missed sensor 1 to 16
921 to 936 ProPAC1 Green sensor failed sensor 1 to 16
937 to 952 ProPAC1 Green sensor late sensor 1 to 16
953 to 968 ProPAC1 Green Constant sensor “off” outside Ready signal sensor 1 to 16
969 to 984 ProPAC1 Green Special sensor missed sensor 1 to 16
1125 to 1140 ProPAC2 High setpoint exceeded sensor 1 to 16
1141 to 1156 ProPAC2 Low setpoint exceeded sensor 1 to 16


1157 to 1172 ProPAC2 Yellow sensor closed sensor 1 to 16
1173 to 1188 ProPAC2 Red sensor open sensor 1 to 16
1189 to 1204 ProPAC2 Green Quick Check sensor “on” outside Ready signal sensor 1 to 16
1205 to 1220 ProPAC2 Green sensor missed sensor 1 to 16
1221 to 1236 ProPAC2 Green sensor failed sensor 1 to 16
1237 to 1252 ProPAC2 Green sensor late sensor 1 to 16
1253 to 1268 ProPAC2 Green Constant sensor “off” outside Ready signal sensor 1 to 16
1269 to 1284 ProPAC2 Green Special sensor missed sensor 1 to16

3rd Party Comms Instructions - Wintriss

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SmartPAC - Enhanced 3rd Party Communications Instructions 1138700D

SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 1

Changing from the System Default DHCP to Static IP Address

For XPE < 3.04 follow these steps:

1. Power down the SmartPAC 2.

SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 2

For XPE > 3.04 follow these steps:

SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 3

For SmartPAC PRO follow these steps:

Figure 1-1. Network Setup Utility

SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 4

Table 1 – Standard Data Tag List

Counter_Good_Parts_No_”RESET” 401011 DWord 0-16,777,216

Press_Stop_Time_Actual 401013 Word 0-9,999

SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 5

Table 1 – Standard Data Tag List (Cont.)

Press_Shaft_Speed 401016 Word (16- 0-9,999

Press_Operator_1 401019 DWord 0-9,999,999

Counter_Scrap_No_”RESET” 401021 Word 0-32,767

Press_State_Code 401022 Word 1-7

SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 6

Table 2 – Expanded Data Tag List

EXPANDED - Counter Tags

Good parts counter 400003 Dword

EXPANDED - Scheduling Tags

Alphanumeric Job String 401028 String (14 Char Max)

EXPANDED - Start Time amd Angle Tags

Resolver angle* 400019 Word

EXPANDED - I/O Status Tags

DipPro Sensor Enable Status (0=Enabled, 1=Disabled) 400514 Word

Procam output status (ProCamPAC Req'd) 400073 Word

WPC input status (WPC req'd) 400074 Word

Input check input status (0-Off, 1-On) 400075 Word

SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 7

EXPANDED - RamPAC Tags RamPAC Module Req'd

RamPAC Counterbalance actual 400045 Word

EXPANDED - AutoSetPAC Tags AutoSetPAC or WaveformPAC Module Req'd

Input 1 forward tonnage 400257 Word

SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 8

Table 3: SmartPAC PRO/ WPC2000 Series Modbus Registers

SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 9

SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 10

SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 11

The following tags only apply if PLC Ethernet Option is present:

SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 12

SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 13

Reporting Downtime and Scrap from SmartPAC

SmartPAC Machine States (Modbus Register 401022)

SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 14

SmartPAC Downtime Reporting Features

State and Reason Tag behavior

Forced Idle Dialog Mode

SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 15

State Tag Value Reason Tag Value

SmartPAC Third Party Communications Firmware Rev. D 12/08/2021 1138700 Page 16

Putting the Press “Back on Line”

Forced Error Dialog Mode

Persist Dialog Mode