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SMI-2 Preliminary Manual ()

1. 0 0 0 cece eee eee 2 10 Table 2 2 Communications Wiring Connections SMI Panel Mount 2 10 Table 3 1 Production Rate Calculation Interval Settings 0 0 0 cee ee ee eee ee 3 14 iv Table of Contents SFC Machine Interface SMI User Manual 1140100 How To Use This Manual This manual shows you how to install set up and operate the SFC Machine Interface SMI Chapter 1 provides an overview of SMI components and operation Chapter 2 shows you how to mount and wire the SMI Installation instructions are provided for both enclosure and panel mount versions and for color and monochrome display options Chapter 3 shows you how to set up the SMI providing instructions for configuring inputs and making production forced dialog and security settings Chapter 4 shows you how to operate the SMI The chapter shows you how to set the parts count preset cycle and scrap count multipliers operations cycle ratio and operator number program Primary items and Job Aliases load jobs and select downtime reasons for machine idle time Chapter 5 documents the system messages that display on the Status line of the SMI display and on the line beneath it Appendix A explains how SFC discovers Primary items at the SMI The Glossary provides definitions of some of the terms used in the manual that may be unfamiliar to you Wiring diagrams are provided at the back of the manual Table of Contents V
2. NOTICE If your password entry is incorrect you are returned to the Security Settings screen which displays the message Invalid password entered beneath the screen title NOTICE If you forget the password contact Wintriss Tech Support and provide the password code displayed in the lower left corner of the Adjust Scrap Data and OP Cycle Ratio screen see Figure 4 3 page 4 3 3 24 Setup SFC Machine Interface SMI User Manual 1140100 3 Press the number key s for the new password value you want your entry appears in the display above the CLR key and press the ENT Enter key NOTICE The maximum value you can enter on the New Password and Confirm Password screens is 9999 When you attempt to enter a value greater than the maximum you are returned to the Security Settings screen which displays the message Password out of range 0 9999 beneath the screen title The Confirm New Password screen which looks identical to the New Password screen except for its title displays with the value 0 shown to maintain password security 4 Press the number key s to confirm the password value you entered in step 3 your entry appears in the display above the CLR key and press the ENT Enter key You are returned to the Security Settings screen The new password you created must now be entered by each user who attempts to access the Setup Menu or make Additional Scrap
3. 000 4 19 Using the Preset Reached Button 0 0 0 0 eee eee ees 4 20 System Messages 220002 eee eee eee 5 1 Messages on the Status Line of the Main Menu 5 1 Messages Beneath the Status Line of the Main Menu 5 2 Messages on the Security Settings Screen 0 0 00 0002 eee 5 2 Appendix A SFC Primary Item Discovery A 1 Table of Contents SFC Machine Interface SMI User Manual 1140100 GlOSSaly cae eed dd te ets eee eee E a de sete G 1 INDCX snes Peewee sete eh ewa eee wee eked eres 1 1 Figures at End of Manual Figure 1 SFC Machine Monitor Wiring Diagram Figure 2 SFC Machine Monitor Press Wiring Diagram List of Figures Figure 1 1 SMI Components Enclosure with Color Display Shown 0 0 0 0 eeceeseeseeesecenseceeeeeneees 1 1 Pigsure 1 2 SML Main Menu s sssicefas iiss secede tel inet R E nates coat E E o cae aki ai es 1 2 Figure 1 3 Help Screen for SMI Main Menu o 0 ce eecceceeeeecsseeeeeeseeesecescesseceseceseeeaeeeeaecaeenaeeseeees 1 5 Figure 2 1 SMI Enclosure Mounting Dimensions Color Display Option Shown eesse 2 3 Figure 2 2 SMI Color Display Mounting and Cutout Dimensions eee eeeeeseceneceteeeeeeeeeeee 2 4 Figure 2 3 SMI Monochrome Display Mounting and Cutout Dimensions 1 0 0 0 ceeeeeeeeeeeeeeeees 2 5 Figure 2 4 SMI Display Installation in Enclosure or Console 0 eeceeseeseceseceeee
4. When the input is energized 1 e 24 Vdc is applied to the input the indicator becomes lit and displays the status On in large letters as shown for the Cycle Input in Figure 3 15 page 3 13 3 12 Setup SFC Machine Interface SMI User Manual 1140100 Input Status Cycle Input On Run Idle Input of Scrap Input ft Disable Inputs oft Input Lines Menu Figure 3 15 Input Status Screen with Cycle Input in On Status You can also view the state of your inputs on the input output LED display on the SMI control module see Checking Input Wiring page 2 16 Making Production Settings The following sections show you how to set the interval SMI uses to calculate the production rate and specify the period of time SMI waits after activation of the Cycle input before changing the machine state from Running to Idle You make these settings on the Production Settings screen see Figure 3 16 which you access from the Setup Menu by pressing the Production Mode Settings button see Figure 3 2 Production Settings Production Rate Production Idle Timer Calculation Interval Active 15 Secs 600 Seconds Maximum Time Between Pulses Deactivated 1 Second Figure 3 16 Production Settings Screen with Defaults Displayed Setup 3 13 1140100 SFC Machine Interface SMI User Manual Setting the Production Rate Calculation Interval The Production Rate Calculation Interval setting enab
5. Job Name 2 To enter a Primary Name identifier press the Edit button at the right of the Primary Name window The Primary Name Job Alias screen displays see Figure 4 9 with the current Primary Name identifier displayed beneath the ENT key the last digit shown in flashing reverse video 3 Press the CLR Clear key to clear the current Primary Name identifier the default is 0 press the number key s for the value you want your entry appears in the display beneath the ENT key and press the ENT Enter key You are returned to the Change Edit End Job screen with your entry displayed in the Primary Name window 4 10 Operation SFC Machine Interface SMI User Manual 1140100 7 NOTICE The maximum length of your entry on the Primary Name Job Alias screen is 20 characters When you attempt to enter a value greater than the maximum your entry defaults to 20 characters If you wish to enter a Job Alias identifier press the Edit button at the right of the Job Alias window The Primary Name Job Alias screen displays see Figure 4 9 with the current Job Alias identifier displayed beneath the ENT key the last digit shown in flashing reverse video Press the CLR Clear key to clear the current Job Alias identifier the default is 0 press the number key s for the value you want your entry appears in the display beneath the ENT key and press the ENT Enter key You are returned to the Change Ed
6. 1140100 SFC Machine Interface SMI User Manual Important Highlighted Information Important danger warning caution and notice information is highlighted throughout the manual as follows A DANGER A DANGER symbol indicates an imminently hazardous situation which if not avoided will result in death or serious injury A 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 vi Table of Contents SFC Machine Interface SMI User Manual 1140100 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 SFC LETS and SBR electro mechanical assemblies and sensors are warranted to be free from defects in material and workmanship under normal use and service for a period of 90 days from date of shipment Wintriss s obligations under this warranty are limited to repairing or replacing at its discretion and at its factory or facility any products
7. Changeover Displays following the Control Setup Transition message see below after you load a new job Also displays whenever you select the Changeover item on the Forced Downtime Selection or Select Downtime screen Indicates that the machine is in the Changeover state Control Setup Transition Displays for a few seconds after you load a new job being followed by the Changeover message see above Indicates that the machine is in transition to the Changeover state Idle Displays whenever the press is not in one of the other machine states and you have selected no reason for planned or unplanned downtime on the Forced Downtime Selection or Select Downtime screen Also displays whenever you press the Return to Production button following SMI power up a period of planned or unplanned downtime or a tool change Indicates that the machine is in the Idle state Offline Time Displays whenever there is no power to the machine or the network is down Parts Preset Reached Displays whenever the value in the Parts Count window reaches the Parts Preset value the Press Return to Production when ready to run message displaying beneath it see Messages Beneath the Status Line of the Main Menu below Press the Return to Production button to clear the message Planned Downtime Displays whenever you select a downtime reason on the Forced Downtime Selection or Select Downtime screen that is as
8. Items Hour and the Pulses per Unit item to 1 EXAMPLE 2 The SMI is installed on a continuous plating line The Cycle input pulses 16 times for each foot of travel You would set Production Rate Units to Feet Minute and Pulses per Unit to 16 To configure the Cycle input for a production rate perform the following steps 1 Press the Production Rate Units button on the Rate Calculation screen repeatedly until the units time period setting you want displays in the Production Rate Units window Available settings are Cycles Minute Cycles Hour Feet Minute Feet Hour Meters Minute Meters Hour Items Minute and Items Hour Press the Pulses per Unit button A screen like the one shown in Figure 3 9 page 3 7 displays with the current pulses unit setting default is 1 second displayed above the CLR key the final digit shown in flashing reverse video The screen is captioned Pulses Per Cycle Pulses Per Foot Pulse Per Meter or Pulses Per Item depending on the Production Rate Units option you selected in step 1 Press the CLR Clear key to clear the current pulses unit setting press the number key s for the number of pulses you want your entry appears in the display above the CLR key and press ENT Enter You are returned to the Rate Calculation screen with your entry displayed in the Pulses per Unit window NOTICE The maximum value you can enter on the Pulses per Unit screen is
9. The SMI2 enclosure is rated NEMA 12 protected against dust and oil If you have ordered the enclosure you must use conduit of the same rating and make proper connections to ensure NEMA 12 protection e Good grounds at the SMI2 are important Make sure that the SMI2 is properly grounded The ground wire from SMI2 should be connected to the main ground point of the machine This may be near the control transformer ground Before starting the installation make sure to check all modes of machine operation Verification that the machine operates and stops properly is extremely important because SMI2 will be connected to the machine s inhibit circuit Do not forget to mark on your electrical prints where you wire in SMI Mounting the SMI The SME is provided in an enclosure or as a panel mount Mounting instructions for both SMI configurations are given in the following sections Before you begin determine a convenient place to mount your SMI Ideally the unit should be close to the machine control so operators and setup personnel can easily see and reach the displays on the touch screen Mounting the SMI2 Enclosure The SMI2 enclosure can be mounted to the machine on a free standing pedestal or on a pendant To mount the enclosure follow these steps referring to Figure 2 1 page 2 3 for mounting dimensions PLACE ENCLOSURE AT A CONVENIENT HEIGHT The SMI2 enclosure should be installed at a convenient height for al
10. 1140100 SFC Machine Interface SMI User Manual Load Next Job Tool Number 35 Job Number SIT Preset 400 Load Next Job Figure 4 10 Load Next Job Screen 3 If the displayed identifiers and preset value are correct press the Load Next Job button You are returned to the Main Menu with the message Control Setup Transition displayed on the Status line After a few seconds this message disappears and the status Changeover displays The Primary Name identifier for the job appears in a window beneath the Change Edit End Job button NOTICE Press the Main Menu button to return to the Main Menu if the displayed job information is incorrect Ending a Job SMI provides two ways of closing out a job when it has finished running You can load a new job by pressing the Load Job button on the Change Edit End Job screen if you are not using the Schedule Interface or the Next Scheduled Job button if you are using the Schedule Interface or you can end the job by pressing the End Job button The End Job function indicates to SFC that the currently running job is finished and that no more time should be logged against it It also forces the SMI into the machine state and downtime reason specified by the default setting in SFC and resets the Primary Name and Job Alias identifiers to zero 0 The End Job condition persists until a new job is loaded To end a currently running job perform the followi
11. 3 23 Restoring Factory Default Settings 0 0 eee 3 23 Changing the System Password 0 0 0 cece eee eee 3 24 Viewing Technical Support Contact Information 3 25 Operation saes y econ eeee Rhee ete ae Setting the Parts Preset 0 2 eee eee eee eee eae 4 2 Making Parts and Scrap Count Settings 00000000 eee 4 3 Configuring the Parts Counter 0 0 cee eee eee 4 4 Configuring the Scrap Counter 0 0 cee eee eee 4 6 Entering Additional Scrap 0 0 eee eee 4 7 Setting Up and Loading Jobs 2 0 0 0 eect eens 4 8 Loading Primary Items for the First Time 0 2 0000000000005 4 9 Loading JOBS ss gee porta wise tag BIE TS A FURR OAK RRO ERS 4 10 Loading the Next Scheduled Job 0 0 0 0 cee ee eee 4 11 Ending a Jobo ersehen e alee tee inte Soe Rye Abe eb te SES eM 4 12 Entering the Operator Number 0 0 0 0 c cece eee eee nee 4 13 Selecting Downtime Reasons 0 0 eects 4 14 Entering Downtime in Response to Forced Dialog 02000 4 14 Entering Downtime To Correct or Augment a Previous Entry 4 16 Using the Return to Production Button 2 2 0 0 0 0c eee eee eee 4 18 Ending a Period of Downtime 0 0 0 cece eee eee 4 18 Clearing the Parts Preset Reached Message 0 0000 ee eee 4 18 Enabling Machine Operation After SMI Power up
12. 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
13. Configuring the Run Idle Input page 3 8 e Scrap Input You must enable the Scrap input in order for the SMI to automatically collect and report scrap counts See Configuring the Scrap Input page 3 11 for additional information Machine States SFC logs all elapsed time at each machine to one of six categories called machine states The sum of all the times assigned to these categories for an individual machine 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 machine time on the basis of downtime reporting and other information it receives from the SMI Machine states are differentiated as follows e Running Time Machine is running and making parts Idle Time Machine is stopped and the reason has not been documented at the SMI e Unplanned Downtime Machine is stopped and the reason has been documented at the SMI with a downtime reason other than Planned Downtime or Changeover see next items e Planned Downtime Machine is stopped and the reason has been documented at the SMI as Planned Downtime NOTICE Planned Downtime should only be associated with dialog reason codes such as lunch breaks meetings training etc Planned Downtime is not used in calculating Overall Equipment Effectiveness OEE and therefore does not reduce the OEE value e Changeover Time Machine is stopped and the reason has been documented at the SMI as Changeov
14. Production Settings Screen with Defaults Displayed 0 eee eeceeseceseccneceeeeeeeeeeeees 3 13 Figure 3 15 Input Status Screen with Cycle Input in On Status ec eeeeeseeeeeeeeeeceeeeseeeeeees 3 13 Figure 3 17 Production Settings Screen with Production Rate Calculation Interval 3 15 Figure 3 19 System Defaults Menu sisirin ana ea a E A E A EEE EEAS 3 17 Figure 3 18 Production Idle Timer Screen with Default Setting Displayed sseseeneecceeeerreeeeeee 3 17 Figure 3 20 Primary Job Alias Selection Screen 0 cece eeseeseceseceseeeeeceseceaeeeseeeseecaaesesecnaeenaeeeaeees 3 18 Figure 3 21 Preset Reached Screen with Default Setting Displayed secneenerereereererrerrereeree 3 19 Figure 3 22 Forced Dialog Settings Screen with Default Settings Displayed 0 eee cere 3 20 Figure 3 23 Forced Dialog Timer Screen with Default Setting Displayed 0 eee cere ceeeees 3 21 Figure 3 24 Security Settings Screen with Default Settings Displayed 0 ee ee eeeeeeeeeenecereees 3 22 Figure 3 25 Confirm Reset Screen nseri ninr devas ets retard E REEE A E E EA 3 23 Figure 3 26 Current Password Screen porssiniincdierni isn ienser i die ia n aeei a iE ereis 3 24 Figure 3 27 About SML S reen vessnreenen aana e A A a R RR 3 25 Fig t 4 1 SMI Man Men iero oee ae at e a a i a EEEE 4 1 Figure 4 2 Parts Preset Screen with Default Setting Displayed eee eseceseeceeeeseceteeeseeees 4 2 Figure 4 3 Adjust Scrap Data and OP Cycle Ratio
15. SMI User Manual Operator Number sas 4 e een ereje o wen Figure 4 12 Operator Number Screen 2 Press the CLR Clear key to clear the current operator number press the number key s for the value you want your entry appears in the display above the CLR key and press the ENT Enter key You are returned to the Main Menu with your entry displayed in the Operator Number window NOTICE The maximum value you can enter on the Operator Number screen is 9999999 When you attempt to enter a value greater than the maximum your entry defaults to 9999999 Selecting Downtime Reasons The following sections show you how to select downtime reasons in response to Forced Dialog and at other times to correct or augment previous downtime selections Entering Downtime in Response to Forced Dialog NOTICE Forced Dialog Mode must be enabled see page 3 20 in order for the Forced Downtime Selection screen to display and prompt the operator to select a downtime reason Whenever the machine being monitored by the SMI has been Idle for the length of time specified by the Forced Dialog Timer see page 3 21 the Forced Downtime Selection screen displays see Figure 4 13 page 4 15 4 14 Operation SFC Machine Interface SMI User Manual 1140100 Changeover Select Mechanical Problem Select Page 1 Electrical Problem Select QA Inspection Select Previous T Page Waiting for Operator Sel
16. displays Enable Inputs Run idle Sense Input Scrap Sense Input Disabled Disabled Require cycle input for change to Running state Not applicable Input Lines Menu Figure 3 10 Enable Inputs Screen with Default Settings Displayed 2 Press the Run Idle Sense Input button to toggle the setting in the Run Idle Sense Input window from Disabled the default to Enabled Note that the setting in the Require cycle input for change to Running state window changes from Not applicable to Yes When the Run Idle input is enabled and a Cycle input is wired the SMI by default records an Idle to Running machine state change only when the Cycle input transitions to high i e 24 Vdc after the Run Idle input transitions to high If you wish to configure the SMI so that the Run Idle input signal is used alone to indicate that the machine is running refer to Configuring Run Idle and Cycle Inputs to Operate Independently page 3 10 3 Press the Input Lines Menu button to return to the Input Lines menu 3 8 Setup SFC Machine Interface SMI User Manual 1140100 Adding a Delay Time You can add a delay time to the Run Idle input just as you can for the Cycle input but the Run Idle input must be enabled for SMI to implement the setting To add a delay time perform the following steps 1 Enable the Run Idle input if you have not already done so see Enabling the Ru
17. pin on the terminal block The LED lights up when 24 volts is applied to the input Simply actuate each of the relays sensors signals connected to the inputs and verify that each LED lights up Checking Machine Inhibit Output Wiring The machine inhibit circuit prevents the machine from being restarted after the interval programmed for the Forced Dialog Timer has elapsed and the Select Downtime Reason screen see Figure 2 7 on page 2 13 has displayed To check the wiring connections for this circuit do the following 1 On the SMI2 Main Menu press the Setup button 2 When the Setup Menu displays press the Forced Dialog Settings button The Forced Dialog Settings screen shown in Figure 2 6 displays Figure 2 6 Forced Dialog Settings Screen 3 On the Forced Dialog Settings screen make sure that the status message beneath the Forced Dialog Mode button is Enabled w Manual Backfill the default setting If the status is Disabled press the Forced Dialog Mode button to change the message to Enabled w Manual Backfill 4 The time interval displayed beneath the Forced Dialog Timer button should be 5 Min the default setting You can set it to a different interval e g 1 minute 10 minutes etc up to Installation 2 12 SFC Machine Interface 2 SMI2 User Manual PRELIMINARY a maximum of 60 minutes by pressing the Forced Dialog Timer button which displays the Forced Dialog Timer screen The current timer set
18. 1 SMI Main Menus chs ni dei leans atin when staan 3 1 Figure 3 2 Set p Menu si c2 ch castvees dete rn i a T E E E TEETE 3 2 Figure 3 3 Input Lines Menu ccsccscccettesateteetsesetosseacevbenestesotedbeeton couebousecetssdbedbesvacebiotegeotceuebenscesteekle 3 3 Figure 3 4 Input Setuip Menta eoira reri e aiaee tan aae eae eters Seed de Ea PER aes 3 3 Figure 3 5 Cycle Input Setup Screen with Default Settings Displayed secseeeeeenesrerrsreerreesre 3 4 Figure 3 6 Cycle Input Setup Screen with Off Delay Settings Displayed eeereeeeeees 3 4 Figure 3 7 Time Delay Screen promi see ete hie ci aie tan eae eee ve aa es a ae 3 5 Figure 3 8 Rate Calculation Screen with Default Settings Displayed 0 eee eeteceneceteeeeeeeeeees 3 6 Figure 3 9 Pulses per Unit Screen seier eiai nets E Ea ad E EE E 3 7 Figure 3 10 Enable Inputs Screen with Default Settings Displayed seeeeeseeeeeeereerereeersreerrsreseee 3 8 Figure 3 11 Run Idle Input Setup Screen with Default Settings Displayed ssesceeeeeeereereereeeesee 3 9 Figure 3 12 Run Idle Input Setup Screen with Off Delay Setting Displayed 0 eee 3 10 Figure 3 13 Enable Inputs Screen with Run Idle Input Enabled 0 0 cee eeeceeeeeeeeeeeneeeeeenees 3 11 Figure 3 14 Input Status Screen with All Inputs in Off Status eeeeeeeeeeeeeeeeeeeeesreerererrrsree 3 12 Table of Contents iii 1140100 SFC Machine Interface SMI User Manual Figure 3 16
19. 1 4 Configuring Parts and Scrap Counts 1 0 0 0 e eee eee eee eens 1 4 Programming Primary Items and Jobs 0 00 e eee eee 1 4 Programming Jobs with the SFC Schedule Interface 00 1 4 Programming Jobs without the SFC Schedule Interface 1 4 Getting Hel px isser chew ws thee s ANS aaa a ita Men Bag ean wage 1 5 Specificatiots srir weet Peet ea ee ea eh A ee eee Pee eee 1 6 Installation 0 000 eee ee 2l Installation Guidelines 0 0 eee eee eens 2 1 Mounting SMU ii ica soa Gee eed a Gea eee ed bee ob ae ee 2 2 Mounting the SMI Enclosure 0 0 eee eee 2 2 Mounting the SMI Panel Mount 0 0 areen 2 3 Wiring SM erary o uaaa Oded muageea cane Ghadean Gob a a aaaea 2 4 Inserting Wires into SMI Terminals 00 0 0 eee eee eee 2 4 Connecting AC Wiring to the SMI Enclosure 0 000000 2 4 Wiring the SMI Panel Mount 00 0 eee e eee eeee 2 5 Connecting Input WINE ssc siai esere noei ee eee 2 7 Connecting Machine Inhibit Output Wiring 0000 2 10 Connecting SMI to Your Ethernet 0 00 02 eee eee eee ee 2 10 Checking Wiring Connections 0 0 cece eee eee ee eee 2 11 Checking Power Connections 0 0 c eee eee eee eee 2 11 Checking Input Wiring svice iite e eee eee eee 2 12 Checking Machine Inhibit Output Wiring 0 000000 2 12 Checking
20. 1024 pulses When you attempt to enter a value greater than the maximum your entry defaults to 1024 3 6 Setup SFC Machine Interface SMI User Manual 1140100 Pulses Per Cycle sas 4 e een ereje o mo Figure 3 9 Pulses per Unit Screen NOTICE To clear an entry on the Pulses Per Unit screen press CLR Clear To clear the last number you entered and backspace to your previous position press BS Back Space To exit the screen without making an entry press ESC Escape 4 Press the Input Setup Menu button to return to the Input Setup menu 5 Press the Input Lines Menu button to return to the Input Lines menu Once you have configured the Cycle input for production units time interval and pulses per unit you must select a Production Rate Calculation Interval on the Production Settings screen see page 3 14 This setting specifies the method SMI uses to calculate the production rate Configuring the Cycle Input to Indicate a Running State The following sections show you how to configure the Cycle input to indicate a Running machine state when a Run Idle input is not wired or when a Run Idle input is wired Configuring the Cycle Input When the Run Idle Input Is Not Wired If you have not wired a Run Idle input to indicate the change from an Idle to a Running state you can set the Cycle input so that its 24 Vdc signal is used by the SMI to indicate that the machi
21. Ethernet Connectivity 00 0 cece eee eee ee 2 14 Setting the IP Address potoan eos Lae Sone ee tele E a at eke ne 2 14 SCIP eb wureeeisveeseg a a de tee eee Sed Accessing the Setup Menu 0 0 ec eee cece eee 3 1 Configuring Inputs h ts bei eee ee oe Ade EEA 3 2 Configuring the Cycle Input 0 00 0 ee eee eee 3 3 Configuring the Run Idle Input 0 00 3 8 Configuring the Scrap Input 0 00 0 cee eee eee 3 11 Viewing Input Status isod a naa A ccc eee eee 3 12 Table of Contents 1140100 SFC Machine Interface SMI User Manual Chapter 4 Chapter 5 Making Production Settings 0 0 0 0 cece cece eects 3 13 Setting the Production Rate Calculation Interval 0 0 3 14 Setting the Production Idle Timer 00 0 0 cece eee eee 3 15 Setting System Defaults 0 0 00 3 17 Changing the Primary Name and Job Alias 00 00 0 enner 3 17 Disabling Stop on Preset Reached 0 c eee eee ee eee 3 18 Making Forced Dialog Mode Settings 0 00 02 c eee eee eee 3 19 Setting Forced Dialog Mode 0 0 eee eee eee 3 20 Setting the Forced Dialog Timer 0 0 00 e cece eee eee 3 21 Making Security Settings 0 0 0 ee eee eeen ee 3 22 Requiring a Password to Access the Setup Menu 004 3 22 Requiring a Password to Make Additional Scrap Entries
22. Manual viii Table of Contents Chapter 1 Introduction The ShopFloorConnect Machine Interface SMI is a data collection and reporting device that you install on a machine to make machine status downtime reasons production rate and parts count information available to ShopFloorConnect SFC This chapter provides an introduction to the SMI It is organized in the following sections e SMI Components below e Inputs and Outputs page 1 2 e Configuring Inputs page 1 2 Machine States page 1 3 Programming and Reporting Downtime Reasons page 1 4 e Programming Primary Items and Jobs page 1 4 Getting Help page 1 5 e Specifications page 1 6 SMI Components SMI is available in an enclosure or as a panel mount for installation in a customer console or enclosure The unit consists of a control module and a color or monochrome display with touch screen as shown in Figure 1 1 Control module Icam i 7 _ A Display with touch screen Communications color shown mono is smaller module Figure 1 1 SMI Components Enclosure with Color Display Shown The touch screen provides labelled buttons that you press to set up and operate the unit The SMI Main Menu the screen that displays when you first power up the SMI is shown in Figure 1 2 page 1 2 Introduction 1 1 1140100 SFC Machine Interface SMI User Manual Status Idle Push Return to
23. Production when ready to run Operator Preset Count Number 0 0 0 Return to Setup Downtime Bradicucn Change Edit End Job Tool Number Figure 1 2 SMI Main Menu Inputs and Outputs The SMI includes four inputs on its control module that provide the unit with machine state production rate and parts count information e Cycle input Indicates when a part has been made or a stage in the production process has been completed and is used to calculate the production rate The Cycle input is also normally programmed to indicate when the machine is running and when it is idle e Run Idle input Can be used in place of the Cycle sensor to indicate when the machine is running and when it is idle e Scrap input Indicates when a part should be counted as scrap e Setup Mode input Indicates when the machine is in a non production mode so the SMI does not collect machine state production rate or parts count information Further details about each of these inputs including wiring instructions are provided starting on page 2 11 The SMI control module provides two outputs that can be used to prevent the machine from being operated when the SMI is programmed to require operator entry of a downtime reason during machine idle time and the operator fails to do so See page 2 14 for additional information about these outputs as well as wiring instructions Configuring Inputs The SMI provides configuration setti
24. When the operator presses the Preset Reached button the Main Menu displays with the message Parts count preset has been exceeded To set the Parts Preset do the following 1 On the Main Menu press the Parts Preset button The Parts Preset screen displays see Figure 4 2 with the current Parts Preset value default is 0 displayed above the CLR key the final digit shown in flashing reverse video Parts Preset sas a e eseon ere een Figure 4 2 Parts Preset Screen with Default Setting Displayed 2 Press the CLR Clear key to clear the current Parts Preset press the number key s for the Parts Preset value you want your entry appears in the display above the CLR key and press the ENT Enter key NOTICE The maximum value you can enter on the Parts Preset screen is 9999999 When you attempt to enter a value greater than the maximum your entry defaults to 9999999 4 2 Operation SFC Machine Interface SMI User Manual 1140100 You are returned to the Main Menu with your entry displayed in the Parts Preset window When the value in the Parts Count window reaches the Parts Preset you entered the Parts Preset Reached message displays on the Status line Making Parts and Scrap Count Settings You can configure the way the SMI counts parts allowing you to maintain parts and scrap counts on machines that produce more than one part on each cycle perform more than one cycle to
25. also load the next scheduled job SMI uses Tool Number as the Primary Name and Job Number as the Job Alias by default and these are the captions that are displayed on the Change Edit End Job screen You can change the items SMI uses for Primary Name and Job Alias on the Primary Job Alias Selection screen see page 3 17 The identifier for each Primary Name must be made available to SFC so that SFC can discover it see Appendix A There are several ways of doing this One is to enter Primary Name identifiers on the Change Edit End Job screen the first time you run the machine 4 8 Operation SFC Machine Interface SMI User Manual 1140100 The following sections show you how to Load Primary items for the first time Load jobs Load the next scheduled job End jobs Loading Primary Items for the First Time NOTICE You can only enter a new item in the fields used for the Primary Name and Job Alias when the machine is stopped If you press the Edit button for either field while the machine is running the message Function disabled while running displays beneath the Status line and the Primary Name Job Alias screen see Figure 4 9 below does not appear You can enter Primary items individually as you set up and load each job or you can enter all Primary items at once when you first set up the SMI The following procedure shows you how to enter all Primary items in one session To load all Pr
26. confirm resetting SFC Machine Interface to factory defaults Figure 3 25 Confirm Reset Screen Setup 3 23 1140100 SFC Machine Interface SMI User Manual 2 Press the Press to confirm button in the middle of the screen The text block on the Press to confirm button is displayed in reverse video while the defaults are being reset When the process is complete you are returned to the Main Menu Changing the System Password The system password is a required entry if either the Password Required to Access Setup or Password Required to Adjust Scrap functions is enabled The default system password set at the factory is 0 zero but you can change it to any numeric value between 0 and 9999 To change the system password do the following 1 On the Security Settings screen press the Change Password button The Current Password screen displays see Figure 3 26 with the value 0 displayed in flashing reverse video above the CLR key The displayed setting is always 0 to maintain password security Current Password sas 4 een ereje o mo Figure 3 26 Current Password Screen Press the number key s for the current password your entry appears in the display above the CLR key and press the ENT Enter key The New Password screen which looks identical to the Current Password screen except for its title displays with the value 0 shown to maintain password security
27. connected to a switch or output from the machine control that actuates i e goes to 24 VDC whenever the machine is not in production mode such as a setup or programming switch or a switch that places the machine in Jog or Inch mode To wire a Setup Mode input connect one wire to input Pin 4 on connector TB2 and the other wire to Pin 5 on connector TB2 see Figure 2 4 Connecting Machine Inhibit Output Wiring To make wiring connections for the machine inhibit output circuit do the following referring to Figure 2 4 and the SMI2 Wiring Diagram Make sure to number all wires in a way consistent with your machine s electrical prints 1 Determine how you will run the wires from your machine control to the SMI2 control module outputs Refer to your machine control manual or other electrical prints You need two wires for each machine inhibit circuit 2 Run the machine inhibit circuit wires to SMI2 through flexible liquid tight conduit to the knockout at the bottom center of the SMI2 enclosure or to the appropriate location on your console If you ordered the enclosure it is rated NEMA 12 protected against dust and oil and you must use NEMA 12 rated conduit and make proper connections to ensure NEMA 12 protection 3 Connect the wires for the machine inhibit circuit to Pins 17 and 18 on connector TBS see Figure 2 4 This output is a dry contact 4A Max 240 VAC or 30 VDC Connecting SMI2 to Your Ethernet To connect the SMI to
28. current timer setting press the number key s for the idle time value you want your entry appears in the display above the CLR key and press the ENT Enter key You are returned to the Production Settings screen with your entry displayed in the Production Idle Timer window NOTICE The maximum value you can enter on the Production Idle Timer screen is 3600 seconds When you attempt to enter a value greater than the maximum your entry defaults to 3600 3 Press the Setup Menu button to return to the Setup Menu 3 16 Setup SFC Machine Interface SMI User Manual 1140100 Production Idle Timer secs 60 sas a e esee ereje o so Figure 3 18 Production Idle Timer Screen with Default Setting Displayed Setting System Defaults The following sections show you how to select the items SMI uses for the Primary name and job alias and how to change the setting that controls whether the machine is stopped or continues to run when the parts preset is reached You access the screens on which you make these settings from the System Defaults Menu see Figure 3 19 which you access from the Setup Menu by pressing the System Defaults button see Figure 3 2 System Defaults Menu Screen Preset Reached Setup Menu Figure 3 19 System Defaults Menu Changing the Primary Name and Job Alias SFC evaluates machine performance using a variable called the Primary item which is the aspect of machine operatio
29. displays with the prompt Push Return to Production when ready to run shown beneath the Status message see Figure 2 8 page 2 15 The status of the machine the SMI is monitoring will be Changeover Planned Downtime or Unplanned Downtime if this was the machine state when the SMI was powered down otherwise the status of the machine will be Idle Press the Return to Production button to clear the prompt The Main Menu should now look like the example shown in Figure 3 1 Note that the Status message is Idle Status Idle Operator Preset Count Number 0 0 0 Return to Setup Downtime production Change Edit End Job Tool Number Figure 3 1 SMI Main Menu To access the Setup Menu see Figure 3 2 page 3 2 from the Main Menu press the Setup button Setup 3 1 1140100 SFC Machine Interface SMI User Manual NOTICE Access to the Setup Menu may require entry of the system password see page 3 22 If the Password screen displays when you press the Setup button press the number key s for the current password and press ENT Enter Setup Menu Forced Dialog Production Mode Settings Settings Security Settings Input Status Lines About SMI System Defaults Main Menu Figure 3 2 Setup Menu The buttons on the Setup Menu allow you to perform the following functions e Input Status Lines Allows you to configure and view the state Off On
30. e Setting the IP Address Setting the IP Address If you encounter problems when installing SMI call Wintriss Tech Support ELECTRIC SHOCK HAZARD e Disconnect main power before installation Turn off all power to the machine and equipment used with the machine Ensure that installation is performed by qualified personnel e Complete all installation and wiring procedures before connecting to the AC power source Failure to comply with these instructions could result in death or serious injury Installation Guidelines Observe the following guidelines when planning your installation e Never run wires for 120V and for lower voltages e g 24V inside the same conduit Run flexible liquid tight conduit for high voltage lines e g 120V power to the knockout at the bottom right of the SMI2 enclosure or to the appropriate location on your console if you have an SMI2 panel mount Run a conduit for low voltage lines i e 24 VDC inputs and machine inhibit outputs through the rear knockout at the bottom left of the SMI2 enclosure or to the appropriate location on your console Run a conduit for the Ethernet cable through the center knockout at the bottom of the SMI2 enclosure or to the appropriate location on your console You may choose to run 24 VDC input wires machine inhibit output wires and Ethernet cable through the same conduit Installation 2 1 PRELIMINARY SFC Machine Interface 2 SMI2 User Manual
31. entries on the Adjust Scrap Data and OP Cycle Ratio screen if either of these functions has been enabled 5 Press the Setup Menu button to return to the Security Menu Viewing Technical Support Contact Information To display the Wintriss Tech Support phone number and information you may need when contacting Wintriss press the About SMI button on the Setup Menu see Figure 3 2 The About SMI screen displays see Figure 3 27 About SMI PLC Code Version V 3 00 HMI Code Version X 3 00 Password Code 65535 For Technical Assistance Call 1 800 586 8324 www ShopFloorConnect com Setup Figure 3 27 About SMI Screen In addition to the Wintriss Tech Support phone number the About SMI screen displays the PLC and HMI code version numbers which you may be asked to provide when requesting technical support and the password code which you will need if you are contacting Tech Support because you have forgotten the SMI system password Setup 3 25 1140100 SFC Machine Interface SMI User Manual The PLC code version number and password code are also displayed on the Adjust Scrap Data and OP Cycle Ratio screen see page 4 3 to provide access to this information when the user is denied entry to Setup Menu To return to the Setup Menu press the Setup button 3 26 Setup Chapter 4 Operation This chapter shows you how to operate the SMI using the buttons available on the SMI Main Menu see Figure 4 1 Sta
32. first time 4 9 loading when loading jobs manually 4 10 production idle timer setting 3 15 production rate setting production rate calculation interval 3 14 setting production rate units and pulses per unit 3 5 R return to production button using 4 18 run idle input checking wiring connections 2 16 configuring 3 8 viewing Off On state 3 12 wiring 2 13 S scrap adjusting the scrap count 4 7 requiring a password to adjust 3 23 setting scrap count multiplier 4 6 scrap input checking wiring connections 2 16 viewing Off On state 3 12 wiring 2 13 security settings making 3 22 setup menu accessing 3 1 requiring password to access 3 22 setup mode input checking wiring connections 2 16 viewing Off On state 3 12 wiring 2 14 specifications SMI 1 6 status messages See messages T technical support 1 5 3 25 tool numbers See primary items aE yA versions SMI displaying 1 5 3 25 W wiring connections AC power 2 9 communications wiring panel mount 2 10 DC power panel mount 2 10 input wiring 2 12 output wiring 2 12 l 2 Index PROPRIETARY RIGHTS This document discloses subject matter in which Wintriss Controls Group has proprietary rights Neither receipt nor possession thereof confers or transfers any right to reproduce or disclose the document any part thereof any information contained therein or any physical article or device or to practice any method or pr
33. produce a part or operate on other parts cycle ratios By default the Cycle input increments the parts counter once for each machine cycle the Scrap input increments the scrap counter once per cycle If you want the parts or scrap counter to increment more than once on each cycle increment once on multiple cycles or increment more than once on multiple cycles you make the appropriate settings on the Adjust Scrap Data and OP Cycle Ratio screen see Figure 4 3 which you access by pressing the Count button on the SMI Main Menu Adjust Scrap Data and OP Cycle Ratio Operations Stenger Count Parts Count Cycle Ratio Stenger 1 eee Count Scrap Count ne Multiplier ne 1 Main 65535 Menu Figure 4 3 Adjust Scrap Data and OP Cycle Ratio Screen with Default Settings Displayed You control the number of times the parts counter increments for each 24 Vdc signal from the Cycle input by setting the Cycle Count Multiplier You specify how many times the scrap counter increments for each Scrap input pulse by setting the Scrap Count Multiplier To configure the number of machine cycles required to produce a part you set the Operations Cycle Ratio The default value for these settings is 1 NOTICE The Scrap Count Multiplier setting is functional only when the Scrap Input is wired to an automated scrap handling system EXAMPLE 1 The SMI is installed on a press brake that requires four bends to make a part You would s
34. 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 Chapter 2 Chapter 3 Introduction 3 cencce svar es serene ey eees cee e ent SMIL Components 2 6 x hnciiey a tied Hearted Se ee Wank PO eee a 1 1 Inputs and Outputs en i208 bobby ele a E E E E aed a Ay ae 1 2 Configuring Inputs cerere enere tei eee Eka ee i EEEE EKE eee 1 2 Machine States anttia ai aiana iraia a nit a La Gerth E ES 1 3 Programming and Reporting Downtime Reasons 000
35. which shall within the applicable period after shipment be returned to Wintriss Controls freight prepaid and which are after examination disclosed to the satisfaction of Wintriss to be defective This warranty shall not apply to any equipment which has been subjected to improper installation misuse misapplication negligence accident or unauthorized modification The provisions of this warranty do not extend the original warranty of any product which has either been repaired or replaced by Wintriss Controls No other warranty is expressed or implied Wintriss accepts no liability for damages including any anticipated or lost profits incidental damages consequential damages costs time charges or other losses incurred in connection with the purchase installation repair or operation of our products or any part thereof Please note It is solely the user s responsibility to properly install and maintain Wintriss controls and equipment Wintriss Controls manufactures its products to meet stringent specifications and cannot assume responsibility for consequences arising from their misuse Wintriss Controls Group LLC 100 Discovery Way Unit 110 Acton MA 01720 Telephone 800 586 TECH 8324 978 268 2700 Fax 978 263 2048 Internet http www wintriss com SFC MACHINE INTERFACE SMI USER MANUAL 1140100 2015 Wintriss Controls Group LLC Table of Contents vii 1140100 SFC Machine Interface SMI User
36. you to set and change the system password require a password for user access to the Setup Menu and to the Additional Scrap item on the Adjust Scrap Data and OP Cycle Ratio screen and return SMI settings to their factory defaults You access the Security Settings screen from the Setup Menu by pressing the Security Settings button see Figure 3 2 Security Settings Password Required Password Required to Access Setup to Adjust Scrap Disabled Disabled Reset to Factory Defaults Change Password Setup Menu Figure 3 24 Security Settings Screen with Default Settings Displayed Requiring a Password to Access the Setup Menu If you wish to restrict access to the Setup Menu you can require that users enter a password to gain entry The required password is the system password which is 0 by default but can be changed via the Change Password button see Changing the System Password page 3 24 To enable the Password Required to Access Setup function perform the following steps 1 On the Security Settings screen press the Password Required to Access Setup button to toggle the setting from Disabled the default to Enabled When this setting is Enabled users must enter the system password in order to access the Setup Menu 3 22 Setup SFC Machine Interface SMI User Manual 1140100 2 Press the Setup Menu button to return to the Setup Menu Requiring a Password to Make Additional Scrap Entries If
37. you wish to restrict access to the Additional Scrap function on the Adjust Scrap Data and OP Cycle Ratio screen see page 4 7 you can require that users enter a password for entry of Additional Scrap items The required password is the system password which is 0 by default but can be changed via the Change Password button see Changing the System Password page 3 24 To enable the password requirement for adjusting scrap perform the following steps 1 On the Security Settings screen press the Password Required to Adjust Scrap button to toggle the setting from Disabled the default to Enabled When this setting is Enabled users must enter the system password in order to make Additional Scrap entries on the Adjust Scrap Data and OP Cycle Ratio screen 2 Press the Setup Menu button to return to the Setup Menu Restoring Factory Default Settings NOTICE You should only use the Reset to Factory Defaults function when you first install the SMI reinstall the SMI on a new machine or need to reset the SMI after certain code updates When you execute and confirm a reset SMI erases all existing settings including downtime reasons If it is necessary to restore SMI settings to their factory defaults perform the following steps 1 On the Security Settings screen press the Reset to Factory Defaults button The Confirm Reset screen displays see Figure 3 25 Confirm Reset Press to
38. your Ethernet do the following 1 Run an Ethernet cable through flexible liquid tight conduit into the knockout at the bottom left of the SMI2 enclosure or to the appropriate location on your console If you ordered the enclosure it is rated NEMA 12 protected against dust and oil and you must use NEMA 12 rated conduit and make proper connections to ensure NEMA 12 protection 2 Plug the Ethernet cable into the Ethernet connector near the center of the SMI2 Main Board Installation 2 10 SFC Machine Interface 2 SMI2 User Manual PRELIMINARY Checking Wiring Connections Before using SMI perform the following checks to make sure that you have wired the unit correctly Checking Power Connections To check SMI2 power connections do the following 1 If you have an SMI enclosure connect AC wires from the enclosure to the power source If you have an SMI2 panel mount make sure that your AC power supply is connected 2 Turn on power to SMI The SMI2 Main Menu shown in Figure 2 5 should display Figure 2 5 SMI2 Main Menu 3 Ifthe Main Menu does not display turn off power to SMI2 and recheck all power connections 4 Ifthe power connections check out and you still cannot get the Main Menu to display call Wintriss Tech Support Installation 2 11 PRELIMINARY SFC Machine Interface 2 SMI2 User Manual Checking Input Wiring Each SMI2 input has a corresponding LED indicator on the board immediately above its input
39. 0 Setup SFC Machine Interface SMI User Manual 1140100 1 On the Input Lines menu press the Enable Inputs button If you have enabled the Run Idle input the Enable Inputs screen that displays should look like the example shown in Figure 3 13 Enable Inputs Runi lIdle Sense Input Scrap Sense Input Enabled Disabled Require cycle input for change to Running state Yes Input Lines Menu Figure 3 13 Enable Inputs Screen with Run Idle Inout Enabled 2 Verify that the Run Idle input is enabled If it isn t enable it following the instructions on page 3 8 3 Press the Require cycle input for change to Running state button to toggle the setting in the window beneath the button from Yes the default setting when the Run Idle input is enabled to No The SMI will now record a machine state change to Running only when the Run Idle input is high 1 e 24 Vdc or to Idle only when the Run Idle input is low i e 0 Vdc 4 Press the Input Lines Menu button to return to the Input Lines menu Viewing the State of the Run Idle Input You can view the state Off or On of the Run Idle input on the Input Status screen see Viewing Input Status page 3 12 Configuring the Scrap Input If you have wired a Scrap input to the SMI the Input Lines menu see Figure 3 3 allows you to enable the Scrap input and view the input s state Off or On Enabling the Scrap Input If you have wi
40. 2 to detect that the machine is running If you want SMI to also count parts you must wire the Cycle input The Scrap contact input should be wired if you want SMI2 or the machine operator to have the ability to increment the scrap part counter the Setup mode input if you want SMI2 to maintain the current machine state and suspend counting of parts during machine setup To make wiring connections run the input wires you intend to use through flexible liquid tight conduit and into the rear knockout at the bottom right of the SMI2 enclosure or to the appropriate location on your console If you ordered the enclosure it is rated NEMA 12 protected against dust and oil and you must use NEMA 12 rated conduit and make proper connections to ensure NEMA 12 protection Wiring a Cycle Input The Cycle input allows the SMI2 to receive a signal whenever the machine cycles incrementing the Good Parts Counter each time the input transitions from low approximately 0 VDC to high 24 VDC The Cycle input signal can come directly from the machine controller as long as it transitions from 0 to 24VDC Ifa control signal at a different voltage level is available you can add a user supplied relay to operate the Cycle input Connect the relay so that its coil is actuated by your control signal and then wire the relay s normally open contacts as follows 1 Connect one wire to input Pin 1 on connector TB2 see Figure 2 4 2 Connect the other wire to P
41. Cycle Input window When this setting is selected the SMI counts each machine cycle as a good part To add a delay time between cycles do the following 1 Press the Cycle Input button to toggle the setting in the Cycle Input window to Off Delay The Status message on the Delay Timer button changes from Deactivated to For Off Delay as shown in Figure 3 6 The value shown in the Delay Timer window in the figure is the default setting 1 second Cycle Input Setup Cycle Input Off Delay Delay For Off Delay 1 Secs Input Setup Menu Figure 3 6 Cycle Input Setup Screen with Off Delay Settings Displayed 2 Press the Delay Timer button The Time Delay screen shown in Figure 3 7 page 3 5 displays with the current delay time default is 1 second displayed above the CLR key the final digit shown in flashing reverse video 3 4 Setup SFC Machine Interface SMI User Manual 1140100 Time Delay secs sas a e een ereje o me Figure 3 7 Time Delay Screen 3 Press the CLR Clear key to clear the current delay time setting press the number key s for the delay time you want your entry appears in the display above the CLR key and press ENT Enter You are returned to the Cycle Input Setup screen with your entry displayed in the Delay Timer window NOTICE The maximum value you can enter on the Time Delay screen is 3600 seconds When you attempt to enter a value greater than t
42. Ethernet cable and the Ethernet connector 3 Ifthe Ethernet connection checks out and one or both of the LEDs still do not come on call Wintriss Tech Support Setting the IP Address You must set the SMI s IP address in order for the unit to communicate with SFC To do so select Setup from the Main Menu then Utilities then Network Parameters The factory default IP address 192 168 100 225 must be changed to the static IP address programmed into ShopFloorConnect for the machine refer to your ShopFloorConnect Workbook for the proper IP address for each machine Press Edit to change the IP address See Figure 2 8 1920168 15 5S AE afefe afefe gt i Figure 2 8 Setting the IP Address Installation 2 14 Chapter 3 Setup This chapter shows you how to set up the SMI providing instructions for configuring inputs and making production Forced Dialog and security settings The chapter is organized in the following sections e Accessing the Setup Menu below e Configuring Inputs page 3 2 Making Production Settings page 3 13 Setting System Defaults page 3 17 Making Forced Dialog Mode Settings page 3 19 e Making Security Settings page 3 22 Viewing Technical Support Contact Information page 3 25 NOTICE For help with any SMI screen touch the screen in its upper left hand corner Accessing the Setup Menu When you power up the SMI the Main Menu
43. Preset Reached Button page 4 20 Push Return to Production when ready to run Displays following SMI power up and whenever the Parts Count Reached message displays see Messages on the Status Line of the Main Menu above Press the Return to Production button to clear the message Messages on the Security Settings Screen Invalid password entered Displays whenever the entry on the Current Password screen is incorrect or the entry on the Confirm Password screen is not identical to the New Password screen entry Re enter the current password or new password Password out of range 0 9999 Displays whenever the entry on the New Password screen exceeds 9999 the screen s maximum value Re enter a new password using a value in the valid range 5 2 Messages Appendix A SFC Primary Item Discovery The Primary item identifiers to be used at the machine the SMI is monitoring are made available to SFC in one of three ways e Primary items can be imported into SFC in a batch file e Primary items can be entered manually into SFC e Primary items can be automatically discovered by SFC the first time they are entered at an SMI In order for SFC to auto discover Primary items at the SMI the SMI must be powered up connected to the network and communicating with SFC and all Primary items to be used at the SMI must be entered and loaded once see page 4 9 SFC creates a record for each new Primary item it di
44. Screen with Default Settings Displayed 4 3 Figure 4 4 Cycle Count Multiplier Screen with Default Multiplier Displayed 0 0 eee 4 4 Figure 4 5 Operations Per Cycle Screen with Default Setting Displayed 00 eee eeeeeree tenes 4 5 Figure 4 6 Scrap Count Multiplier Screen with Default Multiplier Displayed eee 4 6 Figure 4 7 Additional Scrap Screen isci esris esen ete iaei ani iistiid 4 7 Figure 4 8 Change Edit End Job Screen essssessseseerresrsreseeresreessrsrestestrsrenssstesrentessesestessesressreee 4 8 Figure 4 9 Primary Name Job Alias Screen oo cece ceecesessceeeeeesceceseesneceseeseesenecsaeesaeeeaeceaeenaeenseeeaes 4 9 Figure 4 10 Coad Next Job Screen sercan raiar EERE aR leet eae 4 12 Figure 4 11 Confirm End Job Screen wo eee cecceseeeeseceeneceeseecseceseceseseaeeeeesaeecaaesaeeseeeaeesseeeeeeeaaees 4 13 Figure 4 12 Operator Number Screen seision ieina i ein AE E kaei 4 14 Figure 4 13 Forced Downtime Selection Screen esessserseseereesisriesreresreererrreseresresetesessesressresersee 4 15 Figure 4 14 Dialog History Soreeh sonit iiae A n e e i ia NA ER 4 16 Figure 4 15 Select Downtime Screenin a a aa i ie aeaiia iiare 4 17 Figure 4 16 Preset Reached Button Screen cei ceeeceeseeeseeeseceeecsseeeceseceseeeseeeseeeaeeesecnaeeeseeeaeees 4 20 List of Tables Table 1 1 SMI Specifications 0 sc 05 cee ek ee ee ee ee bE eae ene beaten ee ees 1 6 Table 2 1 DC Wiring Connections SMI Panel Mount
45. VVINTRISS PRELIMINARY VERSION The Installation section Chapter 2 of this manual accurately reflects the installation procedures for the SMI 2 The other sections have been adapted from the SMI 1 Manual and should be considered a work in progress with some figures and screenshots being slightly different than the actual product USAF ShopFloorConnect Machine Interface 2 SMI 2 MANUAL Tech Support Hotline 800 586 8324 8 5 EST UNIR Wintriss Controls Group LLC 100 Discovery Way Unit 110 Acton MA 01720 USA Phone 800 586 8324 Fax 978 263 2048 PRINTED IN USA www wintriss com 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
46. alculating 3 14 Setup SFC Machine Interface SMI User Manual 1140100 Production Settings Production Rate Production Idle Timer Calculation Interval Active Instantaneous 600 Seconds Maximum Time Between Pulses Active 1 Second Setup Menu Figure 3 17 Production Settings Screen with Production Rate Calculation Interval Set to Instantaneous The Maximum Time Between Pulses default is 1 second EXAMPLE If the time between pulses is 4 seconds as in the example above set the Maximum Time Between Pulses to 5 seconds as a starting point To make Production Rate Calculation Interval settings perform the following steps 1 Press the Production Rate Calculation Interval button until the setting you want displays in the Production Rate Calculation Interval window The setting cycles from 15 to 30 60 and 120 seconds and then to Instantaneous each time you press the button When you select Instantaneous the status at the bottom of the Maximum Time Between Pulses button changes from Deactivated to Active 2 Ifyou selected Instantaneous in step 1 press the Maximum Time Between Pulses button until the setting you want displays in the Maximum Time Between Pulses window The setting cycles from second to 3 5 10 20 30 60 90 and 120 seconds 3 Press the Setup Menu button to return to the Setup Menu Setting the Production Idle Timer The Production Idle Timer se
47. amps away from the panel s side flange and swing open the enclosure door Run the AC power wires to SMI2 through flexible liquid tight conduit to the knockout in the lower left corner of the enclosure Because SME 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 Connect the ground green or green yellow wire to the setscrew terminal on the ground stud on the bottom of the enclosure near the right side see Figure 2 3 To make the connection strip the wire 1 2 12 7 mm from the end loosen the screw on the terminal insert the exposed wire into the hole and tighten the screw down Connect power wires to the input connectors on the SMI2 control module labelled Line and Neut as shown in Figure 2 3 and the SMI2 Wiring Diagram at the end of this manual ELECTRIC SHOCK HAZARD Do not apply AC power until all other electrical connections and installation procedures are complete Failure to comply with these instructions could result in death or serious injury Wiring the SMI2 Panel Mount AC Wiring Connections To make AC input connections to the SMI2 panel mount do the following referring to Figure 2 3 on page 2 6 or the SMI2 Wiring Diagram Remember to allow plenty of room to make wiring connections 1 Determine how you will bring wiring from your 115 VAC power source or 230 VAC source if applicable
48. are using the SFC Schedule Interface press the Load Next Job button to load the next job see page 4 11 Enabling Machine Operation After SMI Power up To use the Return to Production button to enable machine operation following power up of the SMI do the following 1 With the Push Return to Production when ready to run prompt displayed beneath the Status line following power up of the SMI press Return to Production The message on the Status line changes to Idle and the prompt is cleared NOTICE When you press Return to Production the machine inhibit relays which opened when the SMI was powered up are closed to enable the machine to be started Operation 4 19 1140100 SFC Machine Interface SMI User Manual Using the Preset Reached Button When the Stop On Preset Reached item on the Preset Reached screen is set to Disabled the machine continues to run and the screen shown in Figure 4 16 displays whenever the parts preset programmed for a job has been reached To clear the screen and return to the SMI Main Menu you press the Preset Reached button Perform the following steps NOTICE If the Stop On Preset Reached item on the Preset Reached screen see page 3 18 is set to Enabled the default the machine is stopped and the Parts Preset Reached message displays on the Main Menu Follow the instructions in Clearing the Parts Preset Reached Message page 4 18 to clear t
49. atio default is 1 displayed above the CLR key the final digit shown in flashing reverse video Operations Per Cycle sas 4 e eseon ere een Figure 4 5 Operations Per Cycle Screen with Default Setting Displayed 4 Press the CLR Clear key to clear the current setting press the number key s for the value you want your entry appears in the display above the CLR key and press the ENT Enter key You are returned to the Adjust Scrap Data and OP Cycle Ratio screen with your entry displayed in the Operations Cycle Ratio window NOTICE The maximum value you can enter on the Operations Per Cycle screen is 1024 When you attempt to enter a value greater than the maximum your entry defaults to 1024 5 Press the Main Menu button to return to the Main Menu If you entered an Operations Per Cycle setting in step 4 that value is displayed at the upper right of the Count button You will also notice that a 0 zero displays at the upper left of the Count button This value is a counter that SMI maintains to track the cycles in a multi cycle operation During production the counter increments on each cycle resetting to 0 when the operation has been completed Operation 4 5 1140100 SFC Machine Interface SMI User Manual NOTICE If the SMI is installed on a press brake an N O push button momentary switch should be wired to the Scrap input so that multi cycle operations that are int
50. ault is 1 second displayed above the CLR key the final digit shown in flashing reverse video 6 Press the CLR Clear key to clear the current delay time setting press the number key s for the delay time you want your entry appears in the display above the CLR key and press ENT Enter You are returned to the Run Idle Input Setup screen with your entry displayed in the Delay Timer window NOTICE The maximum value you can enter on the Time Delay screen is 3600 seconds When you attempt to enter a value greater than the maximum your entry defaults to 3600 NOTICE To clear an entry on the Time Delay screen press CLR Clear To clear the last number you entered and backspace to your previous position press BS Back Space To exit the screen without making an entry press ESC Escape 7 Press the Input Setup Menu button to return to the Input Setup menu 8 Press the Input Lines Menu button to return to the Input Lines menu Configuring Run Idle and Cycle Inputs to Operate Independently If you have wired both Run Idle and Cycle inputs and have enabled the Run Idle input see page 3 8 the SMI is set by default to record an Idle to Running machine state change only when the Cycle input turns on after the Run Idle input turns on If you wish to configure the SMI so that the Run Idle input signal is used alone to indicate the change to a Running state perform the following steps 3 1
51. by a machine in a specified period of time SMI calculates the production rate using three user supplied settings the units per time period in which production is measured e g parts minute feet hour etc the number of Cycle input pulses required to produce a unit and the interval during which the SMI collects production rate samples An SFC module that manages the scheduling of jobs on a machine The Schedule Interface is set up by the user in SFC SFC Stands for ShopFloor Connect the data collection software to which the SMI reports downtime reasons parts and scrap counts and other production information G 2 Glossary Index A AC power checking wiring connections 2 15 wiring to SMI enclosure 2 7 wiring to SMI panel mount 2 8 C communications wiring 2 10 cycle input checking wiring connections 2 16 configuring 3 3 viewing Off On state 3 12 wiring 2 11 D DC power panel mount wiring 2 10 default settings restoring 3 23 dimensions See mounting dimensions display SMI installing in enclosure or console 2 6 downtime reasons selecting 4 14 4 16 E enclosure SMI connecting AC wiring to 2 7 installing 2 2 mounting dimensions 2 3 Ethernet checking connections 2 19 connecting to SMI 2 14 ay forced dialog selecting downtime reasons 4 14 setting forced dialog mode 3 20 setting forced dialog timer 3 21 H help screens accessing 1 5 fe inputs c
52. cal article or device or to practice any method or process except ky written permission lor written agreement with Wintriss Controls Group O1 O 10 IND 24V 12V CGND gt WER INPUT WINTRISS lt GND gt C 5V9 J13 Pl LEON TBe INPUTS 5 8 120 240 VAC so 60 HZ INPUTS 5 8 UTPUTS Oe CRUN IDLED Oc CIN 1 4 COM gt Os CIN 5 8 COM gt Oz lt scRAP gt O4 lt setuP gt O10 lt IN 5 O11 IN Oie an 7 O13 an 8 O14 24 O C lt CYC SW 20 240 VAC 20 240 VAC MACHINE CYCLE INPUT PRESS CONTROL TOP STOP CURCUIT MACHINE E MACHINE INHIBIT This input must go on at aprox 90 degrees and off at aprox 270 degrees he machine inhibit output is closed for normal each rotation of the press The SMI uses this input to count press strokes ress operation It opens when the machine and determine when the press is running peration needs to ke inhibited to force the To turn this input on you must apply 24 VDC This voltage can come from perator Fo Enr downtime Feasods internal SMI 24 VDC supply or an external voltage source as long as the ist output e ar ORY contie t pelny patei at 2 amps the Com Grounds are connected together to provide a current return path This is normally connected to the top stop circuit The mac
53. can change the Forced Dialog defaults on the Forced Dialog Settings screen see Figure 3 22 which you access from the Setup Menu by pressing the Forced Dialog Settings button When you are finished you can return to the Setup Menu by pressing the Setup Menu button Forced Dialog Settings Forced Dialog Mode Forced Dialog Timer Enabled w Manual Backfill 5 Min Setup Menu Figure 3 22 Forced Dialog Settings Screen with Default Settings Displayed Setting Forced Dialog Mode The Forced Dialog Mode button on the Forced Dialog Settings screen toggles between three settings e Enabled w Manual Backfill Default Forced Dialog Mode is enabled and all time occurring after the machine has stopped up to the point when the operator selects a downtime reason can be either documented with that downtime reason or left as Idle time the downtime reason in the latter case being assigned to all time occurring after selection of the downtime reason and restarting of the machine The screen on which the operator elects to backfill or forward fill the downtime reason is shown in Figure 4 14 page 4 16 NOTICE Downtime should only be forward filled when the operator discovers a second downtime reason immediately after selecting the first When Forced Dialog Mode is enabled SMI actuates the inhibit relays whenever the machine has been stopped for longer than the interval specified in the Forced Dialog Time
54. display above the CLR key and press the ENT Enter key You are returned to the Adjust Scrap Data and OP Cycle Ratio screen with your entry added to the current value in the Scrap Count window The current Parts Count is displayed in the Parts Count window Operation 4 7 1140100 SFC Machine Interface SMI User Manual NOTICE The maximum value you can enter on the Additional Scrap screen is 65535 When you attempt to enter a value greater than the maximum your entry defaults to 65535 NOTICE The value you enter on the Additional Scrap screen is added to the current value in the Scrap Count window If for example you make an Additional Scrap entry of 5 and the current scrap count is 10 the Scrap Count window would display a value of 15 Scrap you enter manually is not adjusted by the Scrap Count Multiplier 3 Press the Main Menu button to return to the Main Menu Setting Up and Loading Jobs You set up and load jobs on the Change Edit End Job screen which you access from the Main Menu by pressing the Change Edit End Job button Change Edit End Job Tool Number Edit 35 Job Number oe J77 Next Cancel End Changes Job sar aia Figure 4 8 Change Edit End Job Screen The Change Edit End Job screen enables you to enter the Primary Name and Job Alias for the job load the job and if necessary end the job If you are using the SFC Schedule Interface you can
55. dle time from this point forward with the selected downtime reason and leave the Idle period or previous downtime reason intact press the Use Selected Reason From This Time On button NOTICE Downtime should only be forward filled when the operator discovers a second downtime reason immediately after selecting the first You are returned to the Main Menu The entry Changeover is displayed on the Status line if you selected this machine state in step 2 If you selected another downtime Operation 4 15 1140100 SFC Machine Interface SMI User Manual reason the entry Planned Downtime or Unplanned Downtime displays depending on the machine state with which that reason is associated in SFC To verify the specific reason you selected press the Downtime button to access the Select Downtime screen see next section Your selection is highlighted and displayed in reverse video Dialog History CHANGE KEEP Previous Downtime And Use Selected Reason To Reason From This Selected Reason Time On Go Back Figure 4 14 Dialog History Screen NOTICE To return to the Forced Downtime Selection Screen without assigning the downtime reason press the Go Back button Entering Downtime To Correct or Augment a Previous Entry You can correct or augment a downtime reason selection you have made on the Forced Downtime Selection screen using the Downtime button on the Main Menu To do s
56. e e g powder paint line continuous plating line etc and you have set Production Rate Units to Feet Minute Feet Hour Meters Minute or Meters Hour you should select the Instantaneous setting see Figure 3 17 page 3 15 When the Production Rate Calculation Interval is set to Instantaneous the SMI measures the time between cycles or pulses and calculates a production rate based on the Production Rate Units and Pulses per Unit settings on the Rate Calculation screen EXAMPLE If the time between pulses is 4 seconds and Production Rate Units is set to Feet Minute and Pulses per Unit to 3 the production rate would be 5 feet minute i e 60 seconds 4 seconds 15 pulses 15 pulses 3 pulses per unit 5 feet minute If you select the Instantaneous setting you must also specify a Maximum Time Between Pulses to enable the SMI to monitor the production rate accurately during machine interruptions Note that the status displayed at the bottom of the Maximum Time Between Pulses button changes from Deactivated to Active when the Instantaneous item is selected in the Production Rate Calculation Interval window Whenever the interval between pulses exceeds this value SMI assumes that the machine is down and stops counting cycles and calculating production rates After two successive pulses with an acceptable interval following an interruption the SMI resumes counting c
57. e machine inhibit relays open to prevent the machine from being restarted When the setting is changed to Disabled the machine inhibit relays remain closed allowing the machine to remain on 2 Press the Setup Menu button to return to the Setup Menu When the Stop on Preset Reached setting is disabled SMI displays the Preset Reached Button screen see Figure 4 16 page 4 20 when a machine has produced the number of parts programmed for the parts preset To start a new job or continue making parts in the current job the operator presses the Preset Reached button SMI displays the Main Menu with the message Parts count preset has been exceeded shown beneath the Status line Making Forced Dialog Mode Settings The SMI is configured by default to force the operator to document each period of Idle time longer than 5 minutes with a downtime reason This setting is called Forced Dialog Mode If the machine remains idle beyond this 5 minute window SMI activates the machine inhibit relays preventing the operator from restarting the machine until he has selected a downtime reason for that period of Idle time SMI provides the Forced Dialog function to minimize the amount of Idle time reported to SFC allowing Idle time to be documented as one of a programmable list of downtime categories e g mechanical problem electrical problem QA inspection etc Setup 3 19 1140100 SFC Machine Interface SMI User Manual You
58. ect Next lect Page Sensor Fault Selec Figure 4 13 Forced Downtime Selection Screen The Forced Downtime Selection screen provides a menu of downtime reasons from which you can select to document machine Idle time The first item Changeover is actually a machine state rather than a downtime reason and appears on all downtime menus The other downtime menu entries are created in SFC by the user and downloaded to the SMI The screen may be several pages long since up to 32 different user defined downtime reasons may be displayed To select a downtime reason to document a period of machine Idle time do the following 1 On the Forced Downtime Selection screen look for the downtime reason you want using the Next Page and Previous Page buttons to move to additional pages of the screen 2 When you have found the downtime reason you want press the Select button next to it If Forced Dialog Mode is set to Enabled w AutoBackfill machine Idle time up to the time you document it with a downtime reason is assigned to the downtime reason you selected and you are returned to the Main Menu Your downtime reason appears on the Status line If Forced Dialog Mode is set to Enabled w Manual Backfill the Dialog History screen displays see Figure 4 14 page 4 16 To document all Idle time up to the present with the selected downtime reason press the Change Previous Downtime Reason to Selected Reason button To document all I
59. eeeeseceseesaeeseeees 2 6 Figure 2 5 Correct Way to Connect Wire to Terminal 200 0 cece eseeseceneceseceeeeeseeeaeeeeeecaesnaeeeaeees 2 7 Figure 2 6 AC Wiring Connections SMI Enclosure Color Display Shown cesessceseeeeeeees 2 9 Figure 2 7 SMI Control Module with Input Output and Ethernet Connections Labelled 2 12 Figure 2 8 SMI Main Menu with Push Return to Production Prompt seese 2 15 Figure 2 9 SMI Control Module with Input Output LED Display 0 eee ee eeeeeeeeereeeeeeeneee 2 16 Figure 2 10 Forced Dialog Settings Screen oo ee ee cesesseceneceneeeeeceeeceseeeaeecaeceaaecseceeeseeeeaeeseneeaaees 2 17 Figure 2 11 Forced Dialog Timer Screen oo cece neiii i na a a E eh 2 18 Figure 2 12 Select Downtime Reason Screen oo eee cesceseceseceseeeseeeeceeseecsaecsaeceaeceeeeeaeeeseeeaeeeneesaaes 2 18 Fisure 2 13 FilesDownload Screen seccsystscuved ecane aeiee Ee ara PE Eee a E er 2 19 Figure 2 14 Configurator WD S reen snini aia E E E R 2 20 Figure 2 15 Configurator WD Screen with SMI Units Displayed eee cess eeeceeeeereeeeeeeneees 2 20 Figure 2 16 Configurator WD Screen with SMI Unit Selected oo eesceseceeeceneeeseeeeeeeeeeenees 2 21 Figure 2 17 Setting IP Address Screen ccesccscccecsesersecesseeecceeeseceseceaerennseetecoderseeseetecensesaseseess 2 21 Figure 2 18 Configurator WD Message Screen o0 sceeeeecesecesseeseeeseeeseecescesaeceaeccaeceseeeseseaeesseseaaes 2 22 Figure 3
60. er e Offline Time Machine is stopped because there is no power to the machine or the network is down All time during which the machine is stopped for any reason other than a power interruption or network failure is logged by SFC to Idle Time unless a downtime reason or a Planned Downtime or Changeover machine state is reported from the SMI Since Overall Equipment Effectiveness OEE and other efficiency metrics assign high ratings to machines with low Idle Time values SMI has been designed to allow very precise reporting of downtime to SFC and may be programmed to require the operator to select a specific Introduction 1 3 1140100 SFC Machine Interface SMI User Manual 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 Programming and Reporting Downtime Reasons The SMI provides settings that enable you to require operator entry of a downtime reason whenever the machine has been idle for longer than a specified period of time Instructions for making these settings are provided starting on page 3 19 Instructions for operator selection of downtime reasons and their associated states is provided starting on page 4 14 Downtime reasons are created in SFC and downloaded to the SMI Configuring Parts and Scrap Counts You can configure the way in which pa
61. erface SMI User Manual 1140100 Input Lines Input Setup ae ea Enable Inputs Setup Menu Figure 3 3 Input Lines Menu Configuring the Cycle Input If you have wired a PNP type cycle sensor to the SMI see Connecting Input Wiring page 2 11 the Input Lines menu provides access to optional settings you can make to configure the input and a screen on which you can view the input s state Off or On Adding a Delay Time If the machine you are monitoring uses a multi step process that requires more than one cycle to produce a part e g a turret press you can add a delay time to the cycle input to prevent subsequent cycles that occur within that time window from being recorded as good parts You access the screen on which you make this setting by pressing the nout Setup button on the Input Lines menu displaying the Input Setup menu see Figure 3 4 Input Setup Cycle Input Run idle Input Rate Calculation Input Lines Menu Figure 3 4 Input Setup Menu then pressing the Cycle Input button to display to the Cycle Input Setup screen see Figure 3 5 page 3 4 Setup 3 3 1140100 SFC Machine Interface SMI User Manual Cycle Input Setup Cycle Input No additional timing pelay Deactivated 1 Secs Input Setup Menu Figure 3 5 Cycle Input Setup Screen with Default Settings Displayed The default setting for the Cycle input is No additional timing as shown in the
62. errupted due to a bad part can be reset to zero See page 2 13 for wiring instructions Configuring the Scrap Counter NOTICE The Scrap Count Multiplier setting is functional only when the Scrap Input is wired to an automated scrap handling system To set the number of times the scrap counter increments for each Scrap input pulse do the following 1 Press the Scrap Count Multiplier button on the Adjust Scrap Data and OP Cycle Ratio screen The Scrap Count Multiplier screen displays see Figure 4 6 with the current Scrap Count Multiplier default is 1 displayed above the CLR key the final digit shown in flashing reverse video Scrap Count Multiplier ees ere ew eM Figure 4 6 Scrap Count Multiplier Screen with Default Multiplier Displayed 2 Press the CLR Clear key to clear the current multiplier setting press the number key s for the value you want your entry appears in the display above the CLR key and press the ENT Enter key You are returned to the Adjust Scrap Data and OP Cycle Ratio screen with your entry displayed in the Scrap Count Multiplier window NOTICE The maximum value you can enter on the Scrap Count Multiplier screen is 999 When you attempt to enter a value greater than the maximum your entry defaults to 999 4 6 Operation SFC Machine Interface SMI User Manual 1140100 NOTICE The setting displayed in the Operations Cycle Ratio w
63. et the Cycle Count and Scrap Count multipliers to 1 and the Operations Cycle Ratio to 4 EXAMPLE 2 Operation 4 3 1140100 SFC Machine Interface SMI User Manual The SMI is installed on a metal stamping press using a die that produces four parts on each stroke You would set the Cycle Count and Scrap Count multipliers to 4 and the Operations Cycle Ratio to 1 EXAMPLE 3 The SMI is installed on a staking machine that produces two parts assemblies for every three machine cycles You would set the Cycle Count and Scrap Count multipliers to 2 and the Operations Cycle Ratio to 3 If the SMI is installed on a machine that requires multiple cycles to make a part you should wire a Reset switch to the Cycle Sensor to prevent actuation of the input following interruption of a multi operation cycle The Reset switch synchronizes the Cycle Sensor with the parts counter assuring that a part is counted only on the final operation of a multi operation cycle not on an intermediary operation before the part has been completed The Adjust Scrap Data and OP Cycle Ratio screen also enables you to enter scrap items manually using the Additional Scrap button In addition the screen displays the current parts and scrap counts The password code is shown at the bottom left and PLC version number at the bottom center of the screen see Viewing Technical Support Contact Information page 3 25 for further details T
64. he following sections show you how to configure the parts and scrap counters and enter additional scrap Configuring the Parts Counter To set the number of times the parts counter increments for each Cycle input pulse and or the number of machine cycles required to produce a part do the following 1 Press the Cycle Count Multiplier button on the Adjust Scrap Data and OP Cycle Ratio screen The Cycle Count Multiplier screen displays see Figure 4 4 with the current Cycle Count Multiplier default is 1 displayed above the CLR key the final digit shown in flashing reverse video Cycle Count Multiplier as 4 eee ereje o me Figure 4 4 Cycle Count Multiplier Screen with Default Multiplier Displayed 4 4 Operation SFC Machine Interface SMI User Manual 1140100 2 Press the CLR Clear key to clear the current multiplier setting press the number key s for the value you want your entry appears in the display above the CLR key and press the ENT Enter key You are returned to the Adjust Scrap Data and OP Cycle Ratio screen with your entry displayed in the Cycle Count Multiplier window NOTICE The maximum value you can enter on the Cycle Count Multiplier screen is 999 When you attempt to enter a value greater than the maximum your entry defaults to 999 3 Press the Operations Cycle Ratio button The Operations Per Cycle screen displays see Figure 4 5 with the current Operations Cycle R
65. he inhibit relays and preventing the machine from being restarted until entry of a downtime reason The timer is set to 5 minutes by default but you can enter timer settings up to 60 minutes SMI uses the Forced Dialog Timer setting only when Forced Dialog Mode is enabled To change the Forced Dialog Timer setting do the following 1 On the Forced Dialog Settings screen press the Forced Dialog Timer button The Forced Dialog Timer screen displays see Figure 3 23 with the current timer setting default is 5 minutes displayed above the CLR key the final digit shown in flashing reverse video Forced Dialog Timer mins ajaja 4 ean re eo weeny Figure 3 23 Forced Dialog Timer Screen with Default Setting Displayed Setup 3 21 1140100 SFC Machine Interface SMI User Manual 2 Press the CLR Clear key to clear the current timer setting press the number key s for the timer value you want your entry appears in the display above the CLR key and press the ENT Enter key You are returned to the Forced Dialog Settings screen with your entry displayed in the Forced Dialog Timer window NOTICE The maximum value you can enter on the Forced Dialog Timer screen is 60 minutes When you attempt to enter a value greater than the maximum your entry defaults to 60 3 Press the Setup Menu button to return to the Setup Menu Making Security Settings The Security Settings screen see Figure 3 24 allows
66. he maximum your entry defaults to 3600 NOTICE To clear an entry on the Time Delay screen press CLR Clear To clear the last number you entered and backspace to your previous position press BS Back Space To exit the screen without making an entry press ESC Escape 4 Press the Input Setup Menu button to return to the Input Setup menu 5 Press the Input Lines Menu button to return to the Input Lines menu Configuring the Cycle Input for a Production Rate The Cycle input can be configured so the SMI is able to calculate a production rate in the units and time interval appropriate to virtually any machine To configure the Cycle input you specify a unit time period e g items minute feet minute etc and the number of cycles or pulses required to produce each unit You make these settings on the Rate Calculation screen see Figure 3 8 page 3 6 which you access on the Input Setup menu see Figure 3 4 page 3 3 by pressing the Rate Calculation button Setup 3 5 1140100 SFC Machine Interface SMI User Manual Rate Calculation Production Pulses per Rate Units Unit Cycles Minute 1 Input Setup Menu Figure 3 8 Rate Calculation Screen with Default Settings Displayed EXAMPLE 1 The SMI is installed on a CNC machine that produces a part every few minutes The Cycle input pulses once for each part produced You would set the Production Rate Units item on the Rate Calculation screen to
67. he message and enable the machine to be restarted Preset Reached Press to clear Figure 4 16 Preset Reached Button Screen 1 Press the Preset Reached button as instructed on the Preset Reached Button screen The SMI Main Menu displays with the message Parts Count Preset has been exceeded shown beneath the status line 2 To return the value in the Count window to 0 and initiate a new job proceed as follows NOTICE You can also continue to make parts on the current job before loading a new job If you are not using the SFC Schedule Interface program a new Parts Preset value see page 4 2 and press the Load Job button to load a new job see page 4 10 If you are using the SFC Schedule Interface press the Load Next Job button to load the next job see page 4 11 4 20 Operation Chapter 5 System Messages This chapter documents SMI system messages Most messages appear on the Status line of the SMI Main Menu and on the line beneath it two messages display beneath the screen title on the Security Settings screen Documentation for each message includes an explanation of what the message means and instructions for how to respond to the message when a response is necessary The chapter is organized in the following sections Messages on the Status Line of the Main Menu below Messages on the Security Settings Screen page 5 2 Messages on the Status Line of the Main Menu
68. hecking wiring connections 2 16 configuring 3 2 viewing Off On state 3 12 wiring 2 11 IP address setting 2 19 ays job aliases changing default option 3 18 loading when loading jobs manually 4 10 job numbers See job aliases jobs ending 4 12 loading with schedule interface 4 11 loading without schedule interface 4 10 M machine inhibit output s checking wiring connections 2 17 wiring 2 14 machine states 1 3 messages 5 1 mounting dimensions enclosure 2 3 panel mount color display 2 4 panel mount mono display 2 5 N network settings entering 2 19 O operator number entering 4 13 outputs checking wiring connections 2 17 wiring 2 14 P panel mount SMI connecting AC wiring to 2 8 installing 2 3 mounting and cutout dimensions color display 2 4 mounting and cutout dimensions mono display 2 5 wiring 2 8 part numbers See primary items parts configuring SMI response to parts preset reached 3 18 responding to parts preset exceeeded message 5 2 responding to parts preset reached message 5 1 setting cycle count multiplier 4 4 setting operations cycle ratio 4 4 setting parts preset 4 2 password system changing 3 24 replacing a lost password 1 5 3 25 requiring for access to setup menu 3 22 requiring to adjust scrap 3 23 primary items Index 1140100 SFC Machine Interface SMI User Manual changing default option 3 17 loading for the
69. hine state When the input is enabled you can stipulate that the Cycle input must actuate after the Run Idle input actuates in order for the SMI2 to report that the machine is in the Running state Instructions in how to make these settings are provided in Configuring the Run Idle Input page 3 8 Wiring a Scrap Input The Scrap input if wired maintains an automatic count of bad parts incrementing a scrap counter each time the input transitions from low approximately 0 VDC to high 24 VDC To wire the Scrap input using a dry contact connect one wire to input Pin 3 on connector TB2 and the other wire to Pin 5 on connector TB2 see Figure 2 4 You must enable the Scrap input in order for the SMI2 to maintain a count of scrap see Configuring the Scrap Input page 3 11 for instructions Installation 2 9 PRELIMINARY SFC Machine Interface 2 SMI2 User Manual Wiring a Setup Mode Input The Setup Mode input instructs the SMI2 to ignore the Run Idle and Cycle inputs whenever the input transitions from low approximately 0 VDC to high 24 VDC This input enables the machine the SMI2 is monitoring to be run in a non production mode such as during setup or troubleshooting without the SMI2 responding to changes in the running state or to machine cycles During these non production periods the SMI2 holds the current machine state including the downtime reason if one is in effect and does not count parts The Setup Mode input should be
70. hine cycle input is shown connected to a cam switch and of the press control using the internal 24 VDC supply SFC Machine Monitor 2 Press Wiring Diagram DRAWING NUMBER A PIG 2 DATE 8 1 15
71. imary items to be used on the machine so that SFC can discover them perform the following steps 1 On the Main Menu press the Change Edit End Job button The Change Edit End Job screen displays with the settings for the last Primary Name and Job Alias identifiers displayed see Figure 4 8 If this is the first time you are accessing this screen both fields display a 0 the default In the example shown in Figure 4 8 the Primary Name is Tool Number the Job Alias Job Name To enter a new Primary Name identifier press the Edit button at the right of the Primary Name window The Primary Name Job Alias screen displays see Figure 4 9 with the current Primary Name identifier displayed beneath the ENT key the last digit shown in flashing reverse video Figure 4 9 Primary Name Job Alias Screen Operation 4 9 1140100 SFC Machine Interface SMI User Manual 3 Press the CLR Clear key to clear the current Primary Name identifier the default is 0 press the number key s for the value you want your entry appears in the display beneath the ENT key and press the ENT Enter key You are returned to the Change Edit End Job screen with your entry displayed in the Primary Name window NOTICE The maximum length of your entry on the Primary Name Job Alias screen is 20 characters When you attempt to enter a value greater than the maximum your entry defaults to 20 character
72. ime e g cycles min feet hr etc in which the production rate is calculated and the number of Cycle input pulses that produce each unit e If you wire and enable a Run Idle contact SMI2 by default reports a Running state when the Cycle Sensor actuates following actuation of the Run Idle contact You can change this setting so the SMI2 reports that the machine is running when only the Run Idle contact actuates If you do not wire a Run Idle contact you can configure the SMI2 to use the Cycle input to determine when the machine is running by setting the Production Idle Timer See Configuring the Cycle Input page 3 3 for instructions in how to make these settings Installation 2 8 SFC Machine Interface 2 SMI2 User Manual PRELIMINARY Wiring a Run Idle Input The Run Idle input enables the SMI2 to detect when the machine is running and when it is stopped Whenever this input is high 1 e 24 VDC the SMI2 detects that the machine is running i e in the Running state and reports that status to SFC Whenever the input is low i e 0 VDC the SMI2 detects that the machine is stopped i e in the Idle state and reports an Idle status to SFC unless a downtime reason is selected To wire a Run Idle contact input using a dry contact connect one wire to input Pin 2 on connector TB2 and the other wire to input Pin 5 on TB2 see Figure 2 4 You must enable the Run Idle input in order for the SMI2 to use it to detect changes in mac
73. in 5 on connector TB2 24 VDC If no appropriate control signal is available you can use a separate user supplied electronic sensor such as a proximity or photoelectric sensor to provide the Cycle input signal The sensor should be installed in a location where it can sense the completion of a machine cycle and or actuate each time a partis made The sensor should be a PNP solid state device If the monitored machine is used in high speed applications of greater than 300 cycles per second the Cycle input should operate with a 50 duty cycle You need three wires for the machine Cycle Sensor connections an output wire a ground wire and a 24 VDC power wire To wire the sensor do the following 1 Connect the PNP Output wire to input Pin 1 on connector TB2 Installation 2 7 PRELIMINARY SFC Machine Interface 2 SMI2 User Manual 2 Connect the Ground wire to the input Pin 7 on connector TB3 3 Connect the Power In wire to Pin 5 on connector TB2 24 VDC Setup Mode Input Machine Scrap Input Inhibit Output G d Run Idle Input pa Cycle Input 24 VDC 8 aa KAE ee Wy te A SERT DA T Ms bidat eua ay 2 Figure 2 4 SME Input Wiring No settings are required for the Cycle input but there are three optional settings e You can add a delay time to the actuation of the Cycle Sensor enabling you to make accurate parts counts when multiple sensor actuations occur during a single cycle e You can configure the units t
74. indow specifies the number of machine cycles required to produce the number of items set in the Parts Count Multiplier and Scrap Count Multiplier windows You should already have set this item when you configured the parts counter If you haven t perform step 4 of the Configuring the Parts Counter procedure page 4 5 3 Press the Main Menu button to return to the Main Menu Entering Additional Scrap If you have not wired a Scrap input or need to add scrap items to the automated scrap count SMI allows you to enter scrap items manually on the Adjust Scrap Data and OP Cycle Ratio screen You can also view the current scrap count and compare it to the current parts count To enter additional scrap items perform the following steps 1 Press the Additional Scrap button on the Adjust Scrap Data and OP Cycle Ratio screen The Additional Scrap screen displays see Figure 4 7 with the value 0 displayed in flashing reverse video above the CLR key The displayed setting is always 0 Additional Scrap ajajia a elece ere ee een Figure 4 7 Additional Scrap Screen NOTICE Access to the Additional Scrap function may require entry of the system password see page 3 23 If the Password screen displays when you press the Additional Scrap button press the number key s for the current password and press ENT Enter 2 Press the number key s for the scrap value you want your entry appears in the
75. it End Job screen with your entry displayed in the Job Alias window Press the Load Job button at the bottom right of the screen to load the job you have specified You are returned to the Main Menu with the message Control Setup Transition displayed on the Status line After a few seconds this message disappears and the status Changeover displays The Primary Name identifier you entered appears in a window beneath the Change Edit End Job button Press the Return to Production button The Status message changes to Idle Loading the Next Scheduled Job If you are using the SFC Schedule Interface you do not have to enter Primary Name and Job Alias identifiers on the Change Edit End Job screen each time you load a job You simply press the Next Scheduled Job button and SFC loads the next job supplying Primary Name Job Alias and Parts Preset information for you To load the next job scheduled by SFC do the following 1 On the Main Menu press the Change Edit End Job button The Change Edit End Job screen see Figure 4 8 displays NOTICE If you press the Next Scheduled Job button when no jobs have been scheduled in SFC the Load Next Job screen does not display Press the Next Scheduled Job button The Load Next Job screen displays see Figure 4 10 page 4 12 with the Primary Name and Job Alias identifiers and Parts Preset value for that job shown This information is provided by SFC Operation 4 11
76. l users An ideal height is to have the top edge of the unit approximately at chin level Experiment to determine a good height for everybody prior to wiring and mounting 1 Drill four holes for mounting and tap if necessary Mounting bolts are 1 4 20 UseaNo 7 drill and 1 4 20 tap 2 Allow up to 9 in of service loop when performing the wiring connections see Wiring the SMI Also make sure all cables will reach the enclosure Installation 2 2 SFC Machine Interface 2 SMI2 User Manual PRELIMINARY 266 A 10 47 256 10 08 203 2 116 9 8 00 4 60 222 3 203 2 8 75 6X4 Dimensions am INCHES Figure 2 1 SMI2 Enclosure Mounting Dimensions Mounting the SMI2 Panel Mount To install the SMI2 Panel Mount in your enclosure or console perform the following steps 1 2 Cut a 7 5 wide by 6 5 high mounting hole Insert the panel mount SMI2 into the cutout ensuring that it is centered and square Using the panel as a guide mark the locations of the mounting holes Remove the SMI2 panel and drill the mounting holes in your enclosure Please Note The holes in the SMI2 panel are sized for 10 screws Installation 2 3 PRELIMINARY SFC Machine Interface 2 SMI2 User Manual Wiring the SMI Inserting Wires into SMI2 Terminals To insert a wire into a terminal on the SMI2 control module communications module or display follow these steps refer
77. les you to specify how the SMI calculates the production rate of the monitored machine The method SMI uses depends on the type of machine being monitored The setting you select should be appropriate to the production units time interval entries you made for the Cycle sensor on the Rate Calculation screen see page 3 5 If the machine is one on which it is appropriate to measure the production rate in parts or cycles per unit of time e g stamping press CNC machine etc and you have set Production Rate Units to Items Minute Items Hour Cycles Minute or Cycles Hour see page 3 6 you should select one of the numeric settings i e 15 30 60 or 120 seconds The SMI counts the number of cycles that occur within the interval you choose and multiplies the result by the ratio of 60 seconds to the interval producing multipliers of 4 i e 60 15 2 60 30 1 60 60 and 1 2 60 120 The default setting is 15 seconds as shown in Figure 3 16 Wintriss recommends that you set the calculation interval based on the number of cycles or parts the machine makes in a minute as shown in Table 3 1 Table 3 1 Production Rate Calculation Interval Settings Production Rate Calculation Interval Parts Minute Settings Seconds More than 10 15 4 10 30 2 3 60 One 1 or less 120 If the machine is one on which the production rate is most effectively measured in distance travelled per unit of tim
78. n Idle Input page 3 8 2 On the Input Lines menu press the nput Setup button The Input Setup menu displays see Figure 3 4 3 Press the Run Idle Input button to display the Run Idle Input Setup screen see Figure 3 11 Run Idle Input Setup Run Idle Input Delay No additional timing Timer Deactivated 1 Secs Input Setup Menu Figure 3 11 Run Idle Inout Setup Screen with Default Settings Displayed The default setting for the Run Idle input is No additional timing as shown in the Run Idle Input window in Figure 3 11 When this setting is selected the SMI records each 24 Vdc signal from the Run Idle input as a machine state change from Idle to Running 4 Press the Run Idle Input button to toggle the setting in the Run Idle Input window from No additional timing the default to Off Delay The Status message on the Delay Timer button changes from Deactivated to For Off Delay as shown in Figure 3 12 page 3 10 The value shown in the Delay Timer window in the figure is the default setting 1 second Setup 3 9 1140100 SFC Machine Interface SMI User Manual Run Idle Input Setup Run Idle Input Off Delay pelay For Off Delay 1 Secs Input Setup Menu Figure 3 12 Run Idle Input Setup Screen with Off Delay Setting Displayed 5 Press the Delay Timer button The Time Delay screen see Figure 3 7 displays with the current delay time def
79. n on a particular job that primarily determines the machine s efficiency Primary items can be the tool mold or fixture that shapes the material to create the part or it may be the material itself or the specific part being made SMI sets the Primary item to Tool Number by default but you can change it to one of six other options i e Part Setup 3 17 1140100 SFC Machine Interface SMI User Manual Number Mold Number Fixture Number SKU Number Material Number or Item Number depending on the Primary item setting you ve made in SFC SFC tracks jobs that run on a machine using one of four job names or aliases Job Number Work Order MO and Production Order SMI sets the job alias to Job Number by default but you can change it to one of the other options You make these changes on the Primary Job Alias Selection screen see Figure 3 20 which you access from the System Defaults Menu by pressing the Screen button Primary Job Alias Selection Primary Name Selection Tool Number Job Alias Selection Job Number Setup Menu Figure 3 20 Primary Job Alias Selection Screen Your changes display as the field captions on the Change Edit End Job screen see page 4 8 To change the Primary Name and or Job Alias perform the following steps 1 To change the Primary Name press the Primary Name Selection button until the option you want displays in the Primary Name Selection window Primary Name
80. ne is running To do so you set the Production Idle Timer see Setting the Production Idle Timer page 3 15 The Run Idle input must be disabled in order to make this setting Configuring the Cycle Input When the Run Idle Input Is Wired If you have wired a Run Idle input to indicate the change from an Idle to a Running state you can set the Cycle input so that its 24 Vdc signal in conjunction with the 24 Vdc signal from the Run Idle input is used by the SMI to indicate that the machine is running To do so you make a setting on the Enable Inputs screen see Configuring Run Idle and Cycle Inputs to Operate Independently page 3 10 Setup 3 7 1140100 SFC Machine Interface SMI User Manual Viewing the State of the Cycle Input You can view the state Off or On of the Cycle input on the Input Status screen see Viewing Input Status page 3 12 Configuring the Run Idle Input If you have wired a Run Idle contact to the SMI the Input Lines menu see Figure 3 3 provides access to optional settings you can make to configure the input and a screen on which you can view the input s state Off or On Enabling the Run Idle Input If you want the SMI to use the Run Idle input to detect the change from an Idle to a Running machine state you must enable the input To do so perform the following steps 1 On the Input Lines menu press the Enable Inputs button The Enables Inputs screen shown in Figure 3 10
81. ng steps 1 On the Main Menu press the Change Edit End Job button The Change Edit End Job screen see Figure 4 8 displays with the Primary Name and Job Alias identifiers for the currently running job displayed 2 Press the End Job button to end the currently running job The Confirm End Job screen see Figure 4 11 page 4 13 displays 4 12 Operation SFC Machine Interface SMI User Manual 1140100 Confirm End Job Press to confirm end job Cancel End Job Figure 4 11 Confirm End Job Screen 3 Press the Press to confirm end job button You are returned to the Main Menu with the machine state which has been set as the End Job default displayed on the Status line NOTICE You can cancel the End Job command by pressing the Cancel End Job button on the Confirm End Job screen Entering the Operator Number The Operator Number button on the Main Menu is used to document the operator of a machine during a defined data collection period such as a shift To enter the operator number do the following 1 On the Main Menu press the Operator Number button The Operator Number screen displays see Figure 4 12 page 4 14 with the number identifying the current machine operator displayed above the CLR key the last digit shown in flashing reverse video If this is the first time an operator number is being entered a default value of 0 displays Operation 4 13 1140100 SFC Machine Interface
82. ngs for Cycle Sensor Run Idle and Scrap inputs e Cycle Sensor You can add a delay time to Cycle Sensor actuation to maintain accurate parts counts when the machine cycles multiple times in the creation of a single part or to ignore multiple strokes on machines like a turret press where the cycles part relationship is unpredictable You can specify the units time interval i e feet minute meters hour etc in which the production rate is measured and program the number of cycles required for each unit enabling the SMI to calculate a production rate for virtually any machine You 1 2 Introduction SFC Machine Interface SMI User Manual 1140100 can also program the Cycle Sensor to indicate when the machine is running if you don t wire a Run Idle input See Configuring the Cycle Input page 3 3 for further details e Run Idle Contact You must enable the Run Idle input if you want the SMI to use actuation of the input to indicate that the machine is running You can add a delay time to Run Idle input actuation just as you can for the Cycle Sensor If the Run Idle input is enabled and you have wired a Cycle input the SMI is configured by default to detect a Running state when the Cycle Sensor actuates immediately after the Run Idle contact actuates You can change this default setting so that the SMI records a change to the Running state when only the Run Idle input turns on Further information about these settings is provided in
83. o perform the following steps 1 On the Main Menu press the Downtime button The Select Downtime screen displays see Figure 4 15 page 4 17 This screen is identical to the Forced Downtime Selection screen see Figure 4 13 except for its title and the inclusion of a Main Menu button so users can return to the Main Menu without making a selection Both screens display the same menu of downtime reasons Look for the downtime reason you want using the Next Page and Previous Page buttons to move to additional pages of the screen When you have found the downtime reason you want press the Se ect button next to it If Forced Dialog Mode is set to Enabled w AutoBackfill machine Idle time up to the time you document it with a downtime reason is assigned to the downtime reason you selected and you are returned to the Main Menu Your downtime reason appears on the Status line If Forced Dialog Mode is set to Enabled w Manual Backfill the Dialog History screen displays see Figure 4 14 Operation SFC Machine Interface SMI User Manual 1140100 To document all Idle time up to the present with the selected downtime reason press the Change Previous Downtime Reason to Selected Reason button To document all Idle time from this point forward with the selected downtime reason and leave the Idle period or previous downtime reason intact press the Use Selected Reason From This Time On button NOTICE Downtime sho
84. obs page 4 10 for further details 1 4 Introduction SFC Machine Interface SMI User Manual 1140100 Getting Help You can get help for any SMI screen by touching the screen s invisible button in its upper left hand corner This area is identified by a label captioned HELP Figure 1 3 shows the screen that displays when you access help for the SMI Main Menu see Figure 1 2 As instructed at the bottom of the Help screen touch the screen anywhere to return to the previous screen Use the PRESET button to change the counter preset Use the COUNT button to modify the counting parameters Use the OPERATOR NUMBER to change the operator number The SETUP button gives you access to the SMI s initialization settings Use the DOWNTIME button to indicate to SFC why the machine is down Use the RETURN TO PRODUCTION button before you start the machine or to end a downtime event Touch the screen to return to previous menu Figure 1 3 Help Screen for SMI Main Menu When Help screens are insufficient to answer your questions or you are having trouble installing setting up or operating the SMI you can contact Wintriss directly The Wintriss Tech Support contact number 800 586 8324 is displayed on the About SMI screen see Figure 3 27 page 3 25 which also shows the PLC and HMI code version numbers and the password code You will need the version numbers when you contact Wintriss for technical support The password code i
85. ocess except ky written permission lor written agreement with Wintriss Controls Group O1 O 10 IND TBe INPUTS 5 8 O1 lt cye sw gt Oe lt RUN IDLED O3 lt scRAP gt O4 lt setuP gt Oc CIN 1 4 COM gt O C lt GND gt Os CIN 5 8 COM gt ET NETWORK ALTERNATE MACHINE CYCLE SENSOR PNP TYPES PNP UTPUT MACHIN RUN MODED A WINTRISS O10 CIN SD INPUTS 5 8 O11 IN Oie an 7 O13 an 8 O14 24 NNECTION WER INPUT J13 Pl 2 4V 12V CGND gt cGND gt CERN C 5V9 120 240 VAC so 60 HZ UTPUTS 20 240 VAC 20 240 VAC HIBIT OUTPUT R NORMAL MACHINE SFC Machine Monitor 2 Wiri ng Diagram A DRAWING NUMBER FIG 1 DATE 8 1 15 PROPRIETARY RIGHTS This document discloses subject matter in which Wintriss Controls Group has proprietary rights Neither receipt nor possession thereof confers or transfers any right to reproduce or disclose the document ET NETWORK CONNECTION any part thereof any information contained therein or any physi
86. of SMI inputs e Production Mode Settings Allows you to set the Production Rate Calculation Interval Maximum Time Between Pulses and Production Idle Timer e Screen Defaults Allows you to change the default Primary Name and Job Alias which provide the field captions that display on the Change Edit End Job screen see page 4 8 Forced Dialog Settings Allows you to enable Forced Dialog Mode and the set the Forced Dialog Timer e Security Settings Allows you to change the SMI system password and require operator entry of the password for access to the Setup Menu and to the Adjust Scrap function Also allows you to restore SMI settings to their factory defaults e About SMEAllows you to view the Wintriss Tech Support phone number as well as the current SMI firmware version numbers and password code which you may need to provide when you contact Wintriss The password code is also displayed on the Adjust Scrap Data and OP Cycle Ratio screen see page 4 3 which you access by pressing the Count button on the LMI Main Menu Configuring Inputs The following sections show you how to configure the Cycle Run Idle and Scrap inputs and view the state Off On of these inputs as well as that of the Setup Mode input You access the screens on which you make these settings from the Input Lines Menu see Figure 3 3 page 3 3 which you select by pressing the Input Status Lines button on the Setup Menu 3 2 Setup SFC Machine Int
87. provide a way of explaining why a machine is Idle during periods when it is not in a Changeover Planned Downtime or Offline state A setting that forces the operator to select a downtime reason from an menu that displays whenever the machine enters an Idle state see machine state The machine cannot be restarted until a downtime reason is selected One of six categories used by SFC to document production time in order to generate OEE and other production reports The six machine states are Running Idle Planned Downtime Unplanned Downtime Changeover and Offline When the machine is in an Unplanned Downtime state that period of time is further documented with one or more downtime reasons A factor applied to the parts and scrap counters that maintains accurate parts and scrap counts when more than one part or scrap item is produced during a single machine cycle If for example the machine makes two parts per machine cycle the multiplier for that part is 2 A factor used together with the parts and scrap count multipliers to maintain accurate parts scrap count statistics when more than one machine cycle is required to produce a part For example if four cycles are required to make a part the operations cycle ratio for that machine is 4 Glossary 1140100 SFC Machine Interface SMI User Manual production rate Schedule Interface The number of parts produced or distance covered
88. r window preventing the operator from restarting the machine until he has selected a downtime reason which SMI then reports to SFC as the real reason for the machine being stopped 3 20 Setup SFC Machine Interface SMI User Manual 1140100 Enabled w AutoBackfill Forced Dialog Mode is enabled and all time occurring after the machine has stopped up to the point when the operator selects a downtime reason is automatically documented with that reason As in the Enabled w Manual Backfill setting SMI actuates the inhibit relays whenever the machine has been stopped for longer than the interval specified in the Forced Dialog Timer window Disabled Forced Dialog Mode is disabled When this setting is selected SMI will not actuate the inhibit relays when the machine has been idle longer than the Forced Dialog Timer setting and will report all time during which the machine is stopped as Idle time To change the Forced Dialog Mode setting do the following 1 2 On the Forced Dialog Settings screen press the Forced Dialog Mode button until the setting you want i e Disabled Enabled w AutoBackfill or Enabled w Manual Backfill is displayed in the Forced Dialog Settings window Press the Setup Menu button to return to the Setup Menu Setting the Forced Dialog Timer The Forced Dialog Timer setting specifies the length of time the SMI waits after the machine has stopped before actuating t
89. red a Scrap input to the SMI and you want the SMI to increment the scrap counter when the machine makes a bad part you must enable the Scrap input To do so perform the following steps 1 On the Input Lines menu press the Enable Inputs button The Enables Inputs screen displays see Figure 3 10 Setup 3 11 1140100 SFC Machine Interface SMI User Manual 2 Press the Scrap Sense Input button to toggle the setting in the Scrap Sense Input window from Disabled the default to Enabled 3 Press the Input Lines Menu button to return to the Input Lines menu Viewing the State of the Scrap Input You can view the state Off or On of the Scrap input on the Input Status screen see Viewing Input Status next Viewing Input Status The Input Lines menu provides access to a screen on which you can view the state Off or On of the Cycle Run Idle Scrap and Setup Mode inputs You access the Input Status screen see Figure 3 14 by pressing the nput Status Lights button Input Status Cycle Input Run Idle Input Scrap Input Disable Inputs Input Lines Menu Figure 3 14 Inout Status Screen with All Inputs in Off Status The Input Status screen displays an Off On indicator to the right of the caption for each input Disable Inputs is the caption for the Setup Mode input When an input is not energized i e when 0 Vdc is applied to the input its indicator is unlit and displays the status Off
90. ring to Figure 2 2 1 Find the correct terminal and loosen the screw over it by turning the screw counterclockwise Strip the correct wire for this terminal 1 4 6 4 mm from the end Insert the bare wire into the terminal 90 of the way Tighten the screw The metal tooth inside the terminal 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 Tighten screw to clamp wire in tenninal Insert wire here Figure 2 2 Correct Way to Connect Wire to Terminal Connecting AC Wiring to the SMI2 Enclosure To make AC input connections to the SMI2 enclosure do the following referring to Figure 2 3 AC Wiring C and Figure 1 or 2 at the end of the manual Remember to allow plenty of room to make wiring connections 1 Determine how you will bring wiring from your 115 VAC power source or 230 VAC source if applicable to the unit These wires should be connected directly to the machine control supply voltage No 16 wire is recommended use No 14 wire if local codes require it For 115 VAC you need three wires line black neutral white and ground green For 230 VAC wires are black and red with green or green yellow for ground Installation 2 4 SFC Machine Interface 2 SMI2 User Manual PRELIMINARY Loosen the screws on the clamps securing the front panel of the enclosure see Figure 2 1 SMI2 Enclosure M pull the cl
91. rts are counted enabling the SMI to maintain accurate counts for machines that produce multiple items on a single cycle a single item on multiple cycles and different ratios of cycles to parts You can specify the number of machine cycles performed and the number of parts produced on each cycle You can also configure the SMI so that multiple scrap items are counted for each machine cycle See Making Parts and Scrap Count Settings page 4 3 and Configuring the Scrap Counter page 4 6 for further information Programming Primary Items and Jobs Entering Primary item job and part preset information at the SMI is handled differently depending on whether you are using the SFC Schedule Interface Programming Jobs with the SFC Schedule Interface If you are using the Schedule Interface setup and scheduling of jobs at the SMI is performed in SFC The SMI operator however may be responsible for entering and loading Primary items so that SFC can discover them see page 4 9 for instructions on how to enter and load Primary items and Appendix A for a description of the Primary item discovery process The operator must also load each job when its position in the schedule is reached see page 4 11 Programming Jobs without the SFC Schedule Interface If you are not using the Schedule Interface setup information must be entered and Primary items loaded at the SMI at the beginning of each job See Setting the Parts Preset page 4 2 and Loading J
92. s 4 Press the Load Job button at the bottom right of the screen to load the Primary Name identifier you have entered You are returned to the Main Menu with the message Control Setup Transition displayed on the Status line After a few seconds this message disappears and the status Changeover displays The Primary Name identifier you entered appears in a window beneath the Change Edit End Job button 5 Press the Return to Production button The Status message changes to Idle 6 Repeat steps 1 through 5 for each Primary Name item you plan to use at the SMI Loading Jobs If you are using the SFC Schedule Interface you do not have to manually load jobs on the Change Edit End Job screen The Schedule Interface does this for you Instead you use the Next Scheduled Job button as instructed in the next section see Loading the Next Scheduled Job page 4 11 If you are not using the SFC Schedule Interface jobs must be loaded manually on the Change Edit End Job screen using the Load Job button To load a job perform the following steps 1 Onthe Main Menu press the Change Edit End Job button The Change Edit End Job screen displays with the settings for the last Primary Name and Job Alias identifier displayed see Figure 4 8 If this is the first time you are accessing this screen both fields display a 0 the default In the example shown in Figure 4 8 the Primary Name is Tool Number the Job Alias
93. s NOTICE If the Stop On Preset Reached setting on the Preset Reached screen see page 3 18 has been changed from Enabled the default to Disabled the machine continues to run and the Parts Preset Reached message does not display Instead the Preset Reached Button screen appears see Figure 4 16 page 4 20 To clear the screen and return to the Main Menu press the Preset Reached button as instructed in Using the Preset Reached Button page 4 20 4 18 Operation SFC Machine Interface SMI User Manual 1140100 1 With the Parts Preset Reached message displayed on the Status line and the Push Return to Production when ready to run prompt displayed beneath it press Return to Production The message on the Status line changes to Idle and the prompt is cleared replaced by the message Parts count preset has been exceeded NOTICE When you press Return to Production the machine inhibit relays which opened when the Parts Preset was reached are closed to enable the machine to be restarted 2 To return the value in the Count window to 0 and initiate a new job proceed as follows NOTICE You can also continue to make parts on the current job before loading a new job If you are not using the SFC Schedule Interface program a new Parts Preset value see page 4 2 and press the Load Job button to load a new job see page 4 10 If you
94. s required if you misplace the system password The password code and PLC code version number are also shown at the bottom of the Adjust Scrap Data and OP Cycle Ratio screen see page 4 3 which you access by pressing the Count button on the SMI Main Menu Introduction 1 5 1140100 SFC Machine Interface SMI User Manual Specifications SMI specifications are shown in Table 1 1 Table 1 1 SMI Specifications Dimensions Enclosure 8 00 in 203 2 mm x 10 00 in 252 0 mm x 4 00 in 187 2 mm Panel mount Color display 6 43 in 163 2 mm x 5 07 in 128 8 mm x 1 57 in 40 0 mm Mono display 4 33 in 110 0 mm x 3 63 in 92 2 mm x 1 17 in 29 8 mm Control module 3 94 in 100 mm x 3 54 in 90 mm x 3 62 in 92 mm Electrical System Power Input 100 240 Vac 50 60 Hz Parts Counter Preset for maximum count Set to 7 digits Inputs Cycle count PNP 24 Vdc maximum Run lIdle state 24 Vdc On Scrap 24 Vdc On Setup mode 24 Vdc On Outputs 2 stop circuits Contact rating 2 A dry contacts DC 42V AC 30V Introduction Chapter 2 Installation This chapter shows you how to install both enclosure and panel mount versions of the ShopFloorConnect Machine Interface SMI The document is organized in the following sections e Installation Guidelines below e Mounting the SMI Mounting the SMI e Wiring the SMI Wiring the SMI e Checking Wiring Connections
95. scovers If the primary item has been run previously at another SMI SFC adds the new SMI to the list of machines that run that Primary item If the Primary item has not been run previously SFC creates a record for it and associates it with that machine Once records have been created for Primary items at the SMI the SFC user can access the Machine Detail page and associate Standard and Ideal rates using the Rates tab Once auto discovered the new Primary item will be available to the SFC Schedule Interface SFC Primary Item Discovery A 1 1140100 SFC Machine Interface SMI User Manual A 2 SFC Primary Item Discovery Glossary NOTICE Cross references to other glossary entries are shown in italics backfill downtime reason forced dialog machine state multiplier operations cycle ratio One of two options provided by the SMI for assigning downtime once a downtime reason has been selected on a downtime menu A downtime reason is backfilled when it is assigned to the previous period of time up to the present whether that interval was documented as Idle time see machine state or with another downtime reason The other option assigns the selected downtime reason to the period of time from the present forward An SMI setting allows you to automate the backfill option see page 3 20 A reason used to document a period of Unplanned Downtime see machine state Downtime reasons
96. selections cycle from Tool Number to Part Number Mold Number Fixture Number SKU Number Material Number and Item Number 2 To change the Job Alias press the Job Alias Selection button until the option you want is displayed in the Job Alias Selection window Job aliases cycle from Job Number to Work Order MO and Production Order 3 Press the Setup Menu button to return to the Setup Menu Disabling Stop on Preset Reached By default SMI opens its machine inhibit output relay whenever the number of parts programmed for a job on the Parts Preset screen see page 4 2 has been reached There are some applications such as injection moulding where it may be desirable to keep the machine running between jobs You can change the setting that controls whether the SMI s machine inhibit output relay opens or remains closed after a job has been completed on the Preset Reached screen see Figure 3 21 page 3 19 which you access from the System Defaults Menu by pressing the Preset Reached button 3 18 Setup SFC Machine Interface SMI User Manual 1140100 Preset Reached Stop On Preset Reached Enabled Figure 3 21 Preset Reached Screen with Default Setting Displayed To change the Preset Reached setting perform the following steps 1 With the default Enabled setting displayed press the Stop On Preset Reached button The setting toggles to Disabled NOTICE When the Enabled setting is selected th
97. sociated in SFC with the Planned Downtime machine state Indicates that the machine is in the Planned Downtime state Messages 5 1 1140100 SFC Machine Interface SMI User Manual Running at cycles per min Displays whenever the machine is in the Running state The speed of the machine in cycles per minute is displayed to the right of the message being refreshed based on the timing set for the Production Rate Calculation Interval see page 3 14 Unplanned Downtime Displays whenever you select a downtime reason on the Forced Downtime Selection or Select Downtime screen that is associated in SFC with the Unplanned Downtime machine state Indicates that the machine is in the Unplanned Downtime state Messages Beneath the Status Line of the Main Menu Function disabled while running Displays for a few seconds whenever you press a button during machine operation that is not functional when the press is running e g Return to Production Parts count preset has been exceeded Displays when the Return to Production button has been pressed in response to the Parts Preset Reached message see Messages on the Status Line of the Main Menu above and the machine continues to make parts To respond to the message stop the machine immediately Also displays when the Preset Reached button has been pressed in response to the appearance of the Preset Reached Button screen see Using the
98. tart with a Production Idle Timer setting of approximately one and a half times the normal cycle rate of the machine So for example if the machine produces 15 parts per minute the normal cycle time would be 4 seconds and the recommended Production Idle Timer setting would be 6 seconds If this initial setting results in an excessive number of alternating short duration Running Idle states in the SFC database you should lengthen the idle timer window You cannot set the Production Idle Timer unless the Run Idle input is disabled see Enabling the Run Idle Input page 3 8 If the Run Idle input is set to Enabled the status message on the Production Idle Timer button will be Deactivated The Production Idle Timer default setting is 600 seconds The maximum value you can set is 3600 seconds To set the Production Idle Timer do the following NOTICE The Production Idle Timer button must be in an Active state in order to set the Production Idle Timer interval If the status message Deactivated is displayed you must disable the Run Idle input in order to make a setting see page 3 8 1 On the Production Settings screen press the Production Idle Timer button The Production Idle Timer screen displays see Figure 3 18 page 3 17 with the current timer setting default is 600 seconds displayed above the CLR key the final digit shown in flashing reverse video 2 Press the CLR Clear key to clear the
99. the Status line is cleared the status of the machine displayed on the Status line changes to Idle and the machine inhibit relays are closed enabling the machine to be restarted Ending a Period of Downtime To use the Return to Production button to end a period of downtime do the following NOTICE The Return to Production button is functional only when the machine is not running If you press the button when the machine is running the message Function disabled while running displays beneath the Status line 1 With a downtime reason displayed on the Status line press the Return to Production button The machine status displayed on the Status line changes from a downtime reason to Idle NOTICE When you press Return to Production the machine inhibit relays which opened when the Forced Dialog Timer expired and the Forced Downtime Selection screen displayed are closed to enable the machine to be restarted 2 Restart the machine The status displayed on the Status line changes to Running Clearing the Parts Preset Reached Message By default the machine is stopped and the Parts Preset Reached message displays on the SMI Main Menu whenever the number of parts programmed for a job on the Parts Preset screen see page 4 2 has been reached To clear the message and enable the machine to be restarted you must press the Return to Production button Perform the following step
100. ting is displayed above the top right corner of the keypad 5 To test the output wiring decrease the Forced Dialog Timer setting to 1 minute by pressing the 7 key the number above the top right side of the keypad changes to 1 then the ENT for ENTER key You are returned to the Forced Dialog Settings screen with the setting 1 Min displayed in the window beneath the Forced Dialog Timer button 6 If your machine inhibit output wiring is correct you should be unable to restart the machine after one minute has elapsed and the Select Downtime Reason screen see Figure 2 7 has displayed Figure 2 7 Select Downtime Reason Screen If you are able to restart the machine after a minute has elapsed check the machine inhibit output wiring 7 Ifthe machine inhibit circuit is wired correctly and you are unable to prevent the machine from restarting after the forced dialog time call Wintriss Tech Support 8 When you are finished reset the Forced Dialog Timer to 5 minutes the default setting or to a different setting of your choice Installation 2 13 PRELIMINARY SFC Machine Interface 2 SMI2 User Manual Checking Ethernet Connectivity To check that SMI2 is properly connected to your Ethernet do the following 1 Verify that the yellow communication LED next to the Ethernet RJ45 connecter near the center of the board is flashing 2 If one or both of these LEDs are not lit check the connection between your
101. to the unit These wires should be connected directly to the machine control supply voltage No 16 wire is recommended use No 14 wire if local codes require it For 115 VAC you need three wires line black neutral white and ground green For 230 VAC wires are black and red with green or green yellow for ground Installation 2 5 PRELIMINARY SFC Machine Interface 2 SMI2 User Manual Figure 2 3 AC Wiring Connections SMI2 Enclosure 2 Connect the ground green or green yellow wire to a ground stud on your enclosure or console Connect power wires to the input connectors on the SMI2 control module labelled Line and Neut as shown in Figure 2 3 or the SMI2 Wiring Diagram ELECTRIC SHOCK HAZARD Do not apply AC power until all other electrical connections and installation procedures are complete Failure to comply with these instructions could result in death or serious injury Installation 2 6 SFC Machine Interface 2 SMI2 User Manual PRELIMINARY Connecting Input Wiring You can make up to four input connections to the SMI e Machine cycle input e Run idle contact input e Scrap contact input e Setup mode input These wiring connections are made on the series of terminal blocks connectors labelled TB2 TB3 and TB4 located along the bottom edge of the left side of the SMI2 Main board see Figure 2 4 You must wire either a Cycle Sensor or a Run Idle contact input in order for SMI
102. tting allows you to set up the Cycle input so that SMI can use its 24 Vdc signal to detect when the machine is running Normally SMI uses the signal from the Run Idle input to detect the machine s Running state but if you can t or don t want to wire a Run Idle input you can use the Cycle input with the Production Idle Timer setting instead The Production Idle Timer setting specifies an interval during which the machine can be idle without SMI reporting a change in machine state from Running to Idle Without this setting SMI would detect and report to SFC that the machine was Running each time the Cycle input went to 24 Vdc and that the machine was Idle each time the Cycle input went Setup 3 15 1140100 SFC Machine Interface SMI User Manual to 0 Vdc The result would be an alternating series of Running and Idle states that would not accurately reflect a period of continuous Run operation To remedy this problem you set a time window after activation of the Cycle input within which SMI ignores all 0 Vdc Cycle input signals maintaining the initial Running state As long as SMI receives at least one additional Cycle input actuation within the idle timer window it does not report any Idle time If the idle timer window expires before SMI receives a subsequent 24 Vdc signal from the Cycle input it reports the next 0 Vdc signal as Tdle time Wintriss recommends that you s
103. tus Idle Operator Preset Count Number 0 0 0 4 Return to Setup Downtime Production Change Edit End Job Tool Number Figure 4 1 SMI Main Menu The chapter is organized in the following sections Setting the Parts Preset page 4 2 Making Parts and Scrap Count Settings page 4 3 Setting Up and Loading Jobs page 4 8 Entering the Operator Number page 4 13 Selecting Downtime Reasons page 4 14 Using the Return to Production Button page 4 18 NOTICE For help with any SMI screen touch the screen in its upper left hand corner Operation 4 1 1140100 SFC Machine Interface SMI User Manual Setting the Parts Preset NOTICE If you are using the SFC Schedule Interface the Parts Preset is programmed in SFC and downloaded with each new job The Parts Preset value which is displayed in the Parts Preset window on the SMI Main Menu see Figure 4 1 controls the number of parts that are made on a particular job When the value in the Parts Count window reaches the Parts Preset setting SMI performs one of two actions depending on the setting on the Preset Reached screen see page 3 18 e SMI stops the machine and displays a Parts Preset Reached message on the Status line and the Press Return to Production when ready to run prompt beneath it e SMI allows the machine to keep running displaying the Preset Reached Button screen see Figure 4 16 page 4 20
104. uld only be forward filled when the operator discovers a second downtime reason immediately after selecting the first You are returned to the Main Menu The entry Changeover is displayed on the Status line if you selected this machine state in step 3 If you selected another downtime reason the entry Planned Downtime or Unplanned Downtime displays depending on the machine state with which that reason is associated in SFC To verify the specific reason you selected press the Downtime button Your selection is highlighted and displayed in reverse video on the Select Downtime screen NOTICE Press the Main Menu button to return to the Main Menu if you choose not to select a downtime reason Select Select Downtime Changeover Mechanical Problem Select Page 1 Electrical Problem Select Previous Page QA Inspection Select Next ae Page Waiting for Operator Select Maln Select Menu Sensor Fault Figure 4 15 Select Downtime Screen Operation 4 17 1140100 SFC Machine Interface SMI User Manual Using the Return to Production Button The Return to Production button is used in the following circumstances To end a period of downtime so the machine can be restarted To clear the Parts Preset Reached message e To allow operation of the machine after the SMI has been powered up When the Return to Production button is pressed the message displayed beneath

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