AMS Controls MP450 User manual

MP450 Controller
for Cut-to-Length Machines
Operator Manual

ii
Copyright  2008 − AMS Controls, Inc. All rights reserved.
The information contained in this document is proprietary to AMS Controls, Inc., and is not to
e reproduced in any form without the specific written authorization of AMS Controls, Inc.
AMS Controls, Inc. reserves the right to change the contents of this manual without customer
notice or permission. The procedures descri ed in this hand ook must e performed only y
trained, certified industrial electricians in accordance with local, state, federal, and NEC codes
and regulations. While AMS Controls has taken all reasona le care to develop safe procedures,
it accepts no responsi ility for misprints, or for injuries, damages, death, or destruction to
persons or equipment caused as a result of not closely following these instructions. For specific
controller questions, contact AMS Controls Inc.
The most current version of this manual is always availa le at:
www.amscontrols.com/files/manuals/default.asp
AMS Controls, Inc.
12180 Prichard Farm Road
Maryland Heights, MO 63043
314.344.3144 – 1-800-334-5213 (US & Canada) – fax: [phone] – [e-mail]
www.amscontrols.com

MP450 Operator Manual
i
Table of Contents
TABLE OF CONTENTS.............................................................................................................. I
CHAPTER 1: INTRODUCTION............................................................................................. 3
O
VERVIEW .................................................................................................................................. 3
Features................................................................................................................................... 3
CHAPTER 2: MANUAL OPERATIONS ............................................................................... 4
J
OGGING M ATERIAL .................................................................................................................. 4
M
ANUAL S HEAR .......................................................................................................................... 4
CHAPTER 3: PRODUCTION PROCEDURES ..................................................................... 5
S
CREEN N AVIGATION ................................................................................................................. 5
Keypad..................................................................................................................................... 5
Push Button and Front Panel Selector Switches..................................................................... 5
P
ROGRAM A J OB ......................................................................................................................... 6
A
UTOMATIC O PERATION ............................................................................................................ 7
L
ENGTH C ALIBRATION ............................................................................................................... 7
C
LEAR C ONTROLLER M EMOR ................................................................................................. 9
INDEX .......................................................................................................................................... 11

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Chapter 1: Introduction
O er iew
The AMS Controls MP450 is an industrial controller used to control cut-to-length
machinery. Figure 1 shows the front panel of MP450.
Figure 1: The AMS Controls MP450 Controller
Features
The MP450 controller’s features include:
• Accurate length control
• Simple programming
• Easy cali ration

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Chapter 2: Manual Operations
Jogging Material
• To jog material forward using the MP450, turn the jog switch on the
controller to the right (clockwise).
• To jog material in re erse using the MP450, turn the jog switch on the
controller to the left (counter-clockwise).
Manual Shear
To fire the shear manually, press the shear utton .
 Note: The controller must e in Manual mode.

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Chapter 3: Production
Procedures
Screen Na igation
Keypad
The keypad uses hot keys to ena le quick entry into certain screens.
Program Press [Program] to program a Jo Num er, Quantity, and
Length; press it again to specify the next jo to run.
Status Press [Status] to exit the current screen and return to the
Status screen.
Cali ration Press [Cali ration] to cali rate the length management
system; press it again to display the Footage Totalizer.
• To reset the totalizer to zero: When the footage
displays, press [Clear]. The prompt “Enter Code to
Clear Total” displays; enter 1984 and press [Enter].
Enter Press [Enter] to enter or store the current value. [Enter]
can also e used to move to the next value.
Clear Press [Clear] (clear entry) to clear or set an entry ack to
its original value.
Push Button and Front Panel Sele tor Swit hes
Shear Press [Shear] to manually activate the shear.
 Note: The MP450 controller allows this switch to
operate when the machine is stopped.
Halt Select [Halt] to load a coil and to stop the machine

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Run Select [Run] to start the machine after a jo has een
programmed
Jog
(Forward
and
Reverse)
When the machine is in manual mode (i.e., the Run
utton is not lit), turn and hold the Jog switch
clockwise to jog the material forward, turn and hold the
Jog switch counter-clockwise to jog the material in
reverse.
This switch is inactive when the Run switch is lit.
Power This switch turns the controller on and off.
• Turn the switch to the right to apply power to the
controller unit
• Turn the switch to the left to remove power
 Note: If the controller unit has een wired to y-pass this switch, the position
of the switch will have no affect on the controller.
Program a Job
Jo s are composed of a quantity of a specified length. You can program up to 50
different quantities and lengths into the controller. To program a jo ,
1. Select [Program] . The current data entry field highlights; once new data
has een entered, the data field starts linking.
 Note: Pressing [Clear] while the data field is linking re-loads the
original value into the data field. Pressing [Enter] saves new data
and highlights the next field.
2. In the Job Number field, enter a num er to assign to this jo (a value etween
1 and 50).
3. In the Quantity field, enter the num er of parts you want to create (up to 999).
4. In the Length field, up to 999 feet and 11.999 inches.

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5. The controller displays the message “Pause After Job xx?” (where xx is the
jo num er assigned in step 1). Select:
- es to have the machine halt automatically after the selected jo num er is
finished.
- No to have the machine change lengths “on-the-fly” and run the jo
following the selected jo without first stopping.
 Note: To restart the machine after an automatic halt, press [Run].
 Note: To increase productivity, additional jo s can e programmed while the
machine is running previously programmed jo s.
Automatic Operation
The MP450 runs all programmed jo s automatically.
• To start the machine after all desired jo s have een programmed, press
[Run] .
• To stop the machine at any time, press [Halt] .
The machine halts automatically when all programmed jo s are completed.
 Note: If the encoder is counting in the negative direction, change the encoder
direction in the Setup Screen as descri ed previously.
Length Calibration
 Note: Cali ration is typically required only during machine startup, although
changing coil stock may sometimes require a cali ration as well.
Length cali ration adjusts for errors in the size and tracking of the measuring
wheel and is expressed as a percentage, with 100% eing no correction. Increasing
the correction factor causes the parts to ecome longer and decreasing the value
shrinks the parts.
The MP450 controller’s length cali ration feature automatically computes a new
correction factor. Length Cali ration should e used any time part lengths are
incorrect in a consistent manner (e.g., all parts 1mm too long, etc.).
 Note: When calculating the correction factor, make several parts (6 to 10) and
use the average of these parts for the part length. The first part produced

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should not e used in this calculation since it may e inaccurate due to shear
reaction or other variances.
To cali rate the MP450 controller,
1. With the controller powered on, press [Calibration] . The display
prompts you to enter a cali ration length.
2. When the prompt “Enter Length for Cali ration” displays, enter a part length.
 Note: The longer a part length you enter, the more accurate the
cali ration will e. The minimum length that can e programmed
for cali ration is 5 feet; the maximum length that can e
programmed for cali ration is 40 feet.
The message “Load Coil, Then Cycle Shear” displays.
3. While in Manual mode, load a coil using the Jog switch and, with the material
slightly past the shear, press [Shear] . The message “Press Run to Start
Cali ration” displays.
4. Press [Run] . The machine starts, produces one part of the cali ration
length, and stops automatically.
5. Carefully measure the part produced
6. When the prompt “Enter Measured Length” displays, enter the measured part
length. The controller is now cali rated.
 Note: If the computed correction factor is greater than 110% or
less than 90%, the “Cali ration Out of Range” error message
displays and the cali rate cycle is ignored.

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Clear Controller Memory
Sometimes electrical disruptions, such as power surges, can alter the controller’s
memory, resulting in erratic controller operation. To remedy this, you must re-set
(erase) the memory and then re-cali rate the controller.
To reset the memory on the controller,
1. Turn the device off, then ack on.
2. Press [5] while the startup screen is showing.
 Caution: Clearing the controller memory clears out all jobs that are
programmed into your controller and re-sets all setup parameters except
encoder direction to their default values. Be sure you have all this data
recorded elsewhere before clearing memory!

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Index
A
Automatic Operation, 7
C
Cali rate Trim, 7
Cali ration
procedure, 7
Clear Controller Memory, 9
Controller Memory
clear, 9
Correction Factor, 7
F
Front Panel Selector Switches, 5
J
Jo
programming, 6
Jog, 4
Jogging Material, 4
K
Keypad, 5
L
Length Cali ration, 7
M
Manual Shear, 4
Material
jogging, 4
MP450S Features, 3
O
Overview, 3
P
Production Procedures, 5
Program a Jo , 6
Push Button and Front Panel Selector Switches,
5
S
Screen Navigation, 5
Selector Switches
Front Panel, 5
Shear, 4
Start the Machine, 7