AMS MP328OL User manual

Model
MP328OL
Gripper & Backguage Controller
Reference Manual
Page 1 ______________________________________ Introduction
Page 3 _______________________________ Interface Description
Page 4 _________________________Setup Mode and Parameters
Page 14 ______________________________________Referencing
Page 16 ___________________________________ Program Mode
Page 17 ___________________________________ Run Operation
Page 19 ____________________Configuration and I/O Definitions
Page 20 _____________________________________Specification
Page 22 _________________________________ Mounting Details
Page 23 ____________________________ Troubleshooting Guide
Page 27 ________________________ Electrical Interface Diagram

AMS Controls 1MP328 Gripper Controller
03-15-06
MP328OL Gripper Controller
AMS Controls has been supplying length control systems to the
metal fabricating industry since 1978 and has built a reputation of
producing high quality and reliable controllers.
The MP328 Gripper controller is a cost effective controller designed
to perform multiple bends on a sheet of metal and will use a gripping
function to hold the metal and to sequence it through each bend..
The MP328 is housed in a compact 8.00” x 12.50” wide x 2.25” deep
enclosure and requires a single 24 VDC power supply for operation.
Copyright © 2006 by AMS Controls, Inc. All Rights Reserved

AMS Controls 2MP328 Gripper Controller
03-15-06
MP328 Open Loop Version 13/14 Controller
Operation & Reference Manual
AMS Controls, Inc.
12180 Prichard Farm Road
Maryland Heights, MO 63043
Phone [phone] • Fax [phone]
!! WARNING !!
AMS CONTROLS, INC. reserves the right to change the contents of this manual without
customer notice or permission. Although every effort is made to insure the correctness
off this manual, it should be noted that AMS CONTROLS, INC. is not responsible for
personal or equipment damage caused by the contents of this manual. It is not the intent
of this manual to cover every possible revision or version of controller. For specific
controller questions contact AMS Controls, Inc.

AMS Controls 3MP328 Gripper Controller
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Front Panel Components and Description
The Model MP328 front panel has three push button switches, a 16
key keypad, and a two line 48 character liquid crystal display.
The three push buttons provide the following functions:
CYCLE
This push button will open the gripper jaws and
will reset the sequence
RUN
Press to initiate an automatic move sequence
HALT
Press to manually stop the guide movement
The keys provide the following functions:
SETUP
Press to enter the setup mode. The setup mode is used
to enter specific parameters about the Gripper.
∗
Press the asterisk key to exit the setup or programming
modes. Also known as the STATUS key to display current
position, etc.
PRG
Press to program a new set position. While in
the program mode, the new position will flash.
ENT
Press to store the values entered in the setup
and program modes.
CE
Press to clear an incorrect entry value before
the “ENT” key is pressed. Also used to clear any errors reported
by the controller.

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Setup Mode
Note: The following descriptions include all possible SETUP
PARAMETERS and there are some parameters that are not
used for every application. Only use the ones that apply for
your particular machine.
The SETUP mode is used when the MP328 is initially installed to
configure it to the particular characteristics of the Gripper. The
SETUP mode is entered by pressing the “Set Up” key and the mode
can be exited by pressing the “∗” key. When power is applied to the
controller, the built-in diagnostics check the memory for data
retention.
If an error is detected, the memory is automatically cleared and the
SETUP mode is entered to indicate that this data should be
reentered. The setup values are entered in the order shown below
and an explanation of each parameter is given. A form is provided in
the back of this manual for recording the setup parameters of your
machine. This form should be completed after your machine has
been installed and properly adjusted.
To enter the SETUP mode, press the “Set Up” key. The following
display will appear.
Selecting “1” will allow the operator to adjust the following
parameters:
1=Configure 2=In/Out
3=Loc/Remote 4=Reference

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Reference Mode
The REFERENCE MODE parameter tells the MP328 where the
reference switch is located. The reference point is the center of the
brake where the bend occurs. If the switch is close to the reference
point and most of the moves of the Gripper occur “behind” the
switch, the REFERENCE MODE is NEAR. If the switch is behind
the Gripper and most of the moves are in “front” of the switch, the
REFERENCE MODE is FAR. Use any number key to toggle the
choices.
Far Reference Mode
Motor
Lead Screw
Brake
Point
Reference
Far Reference
Switch, Normally
Open
Reference Position
Near Reference Mode
Motor
Lead Screw Brake
Reference
Position
Point
Reference
Near Reference
Switch, Normally
Open

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The switch for a NEAR REFERENCE MODE must be normally open
and remain closed as long as the Gripper is on the switch or closer
to the reference point than the switch. The switch for a FAR
REFERENCE MODE must be normally open and remain closed as
long as the Gripper is on the switch or farther away from the
reference point than the switch.
Ref. Pos.
The REFERENCE POSITION is the distance from the reference
point (typically the bend point on the brake) to the inside jaws of the
gripper at the point the “home” switch is detected (after being
referenced).
Metal Flow
This parameter specifies whether the metal is fed from one side of
the brake and the formed parts comes out of the other (NORMAL);
or if it is fed through the backside of the brake, (REVERSE). If this
parameter is set to NORMAL, the machine should move to the total
sheet length plus the CLEARANCE DISTANCE when there is a new
program. When REVERSE is selected, it will move to the new
CLEARANCE DISTANCE.
Ignore First Bend
When used in conjunction with an MP338 backgauge, the MP328
will need to ignore the first bend of the part. The first bend will be
controlled by the MP328 backgauge device (or “backstop”).
If “Yes is selected, the gripper will position itself the length of the part
minus the length of the first leg of the part. The gripper will position
itself for brake #2 and brake #3, ignoring the first brake.
If “No” is selected, the gripper will work normally, positioning itself
the full distance of the overall part length plus the overshoot
distance.
Enable Creep Mode
This defines what type of feedback the MP328 will be looking for
when it searches for the part. If the Enable Creep Mode is set to
“Yes”, it will look for a detector switch mounted on the gripping
device. This detector will signal that controller that it has found the
sheet.
If the mode is set to “No”, the controller uses only encoder feedback
to locate the sheet. This requires that the sheet be consistently in
the same location from one part to the next. This will be determined
by the backstop device.

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Eject Mode Speed
The MP328 controller can be put into an “Eject” mode that will
enable the gripper device to push the part past the brake so that it is
easily and safely available to the operator. After the last bend is
completed, the gripper device will be sent to position “0.00”, which is
directly under the brake. After reaching this point it will return to the
home position.
Clearance Dist
This parameter determines the point at which the gripper will move
to when a new program is entered or after completion of a
sequence. CLEARANCE DIST plus ACTUAL PART LENGTH will
determine the position of the guide between sequences.
Brake Dwell Dn
BRAKE DWELL DOWN is the time it takes for the brake to move
from the top of the stroke to the bottom of the stroke. The range of
time allowed is 0.001 to 9.999 seconds and can be set to the
nearest millisecond.
Brake Dwell Up
BRAKE DWELL UP is the time necessary for the brake to return
from the bottom to the top of its stroke
Speed Logic
If the controller is set up for two speed logic, the MP328 controller
has four outputs which control the speed and direction of the
machine. To accommodate more than one wiring possibility, the
controller may be run with one of two different SPEED LOGIC
settings: FORWARD/SLOW or FAST/SLOW. The controller
outputs are defined differently for each logic setting. The outputs,
their definitions, and their states in various conditions are shown in
tables 4-1 and 4-2. Any number key can be used to toggle between
FORWARD/SLOW and FAST/SLOW. Select the appropriate
SPEED LOGIC to match your machine wiring configuration.
Machine State
Run Fast
Run Slow
Jog Fwd
Halt
Jog Rev
Output 1 (FOR)
ON
ON
ON
OFF
OFF
Output 2 (SLOW)
OFF
ON
OFF
ON
OFF
Output 3 (REV)
OFF
OFF
OFF
OFF
ON
Output 5 (RUN)
ON
ON
OFF
OFF
OFF
Table 4-1. Status of Outputs in Forward-Slow
Note: All Jogging and Referencing is performed at fast speed

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Machine State
Run Fast
Run Slow
Jog Fwd
Halt
Jog Rev
Output 1 (FOR)
ON
OFF
ON
OFF
OFF
Output 2 (SLOW)
OFF
ON
OFF
OFF
OFF
Output 3 (REV)
OFF
OFF
OFF
OFF
ON
Output 5 (RUN)
ON
ON
OFF
OFF
OFF
Table 4-2. Status of Outputs in Fast-Slow
Note: All Jogging and Referencing is performed at fast speed
Min Slow Distance
This parameter is used to put the line into slow speed (if using two
speed logic). The controller will automatically calculate when to start
slowing down and then this distance is added to it (if the DECEL
MODE is set to AUTO). Increase this value for a longer slow
distance. Decrease this value for a shorter slow distance. A longer
slow distance can improve part accuracy but too long a value can
slow production. The distance should be set long enough that the
material fully reaches the slow speed before stopping.
A minimum amount of slow distance can be manually set by this
parameter. It is added to the calculated slow distance to extend the
time spent in slow speed (if the DECEL FACTOR is set to AUTO).
The MP328 controller calculates the distance from the programmed
position that the machine should shift into slow speed. This is based
on the speed of the material and the deceleration characteristics of
the machine.
When the DECEL FACTOR AUTO setting is used, it is best to set
this parameter to a few inches initially until the system has been
calibrated and the controller has had a chance to get accustomed to
the behavior of the machine. When the machine is running good
parts repeatedly, reduce the MINIMUM SLOW DISTANCE as much
as possible to increase the production rate.
This value should be set long enough that the material fully reaches
the slow speed before stopping.
Overshoot Dist
The MP328 will always move the backgauge toward the target in a
forward direction (toward the reference point). When moving away
from the reference point to make a bend, or a FAR REFERENCE,
the backgauge will overshoot the target by the OVERSHOOT
DISTANCE and approach the target in a forward direction. This is
done to keep any machine “slop” behind the backgauge.

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The allowable range is 0.0 to 50.0 inches. The distance that is
entered should be large enough so that the backgauge can get up to
full speed before stopping. The default value is 10.0000 inches.
Tolerance
The controller can check for the backgauge to be within a specified
TOLERANCE. If the machine has not stopped within this
TOLERANCE, the controller will halt and an error will be displayed.
The TOLERANCE should be set small enough to get acceptable
parts but wide enough to avoid production interruptions. The
controller allows values from 0.0005 inches to 10.0000 inches. The
default value for TOLERANCE is 1.0000 inches.
Stopping Mode
The STOP REACTION time represents the time delay from the time
that the controller turns off the movement outputs until the
backgauge actually stops. The user has a choice of three
STOPPING MODES: AUTO, MANUAL, or OFF. Use any number
key to toggle through the choices.
AUTO: The controller turns off the movement outputs
prior to the actual brake point to allow for the
momentum and inertia of the machine. A new STOP
REACTION time is calculated after each stop based on
the average stopping time for several cycles. This
parameter may be overridden, but the value will be
modified on the next part that is run. The maximum
value is 9.9999 seconds.
MANUAL: The controller turns off the movement outputs
prior to the actual brake point as above. However,
when in MANUAL, the controller does not recalculate a
new STOP REACTION time after each stop. Whatever
value is manually entered remains constant. The
maximum value is again 9.9999 seconds.
OFF: A STOP REACTION time is not calculated and is
not used at all by the controller. The movement
outputs are turned off when the backgauge position is
equal to the programmed length of the bend. This
should cause bends to come out short due to the
momentum of the machine and material during

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stopping. Also, when the STOP MODE is set to OFF a
tolerance test is not performed.
The default mode for STOP REACTION time is AUTO which is the
recommended mode of operation.
Stop Reaction
The STOP REACTION is the time it takes (in seconds), for the
backgauge to come to a stop after the outputs are turned off. It is
adjusted automatically after every stop by the controller if the
STOPPING MODE has been set to AUTO.
Decel Factor Mode
On two-speed machines, a DECELERATION (DECEL) FACTOR is
used by the MP328 controller when changing from fast to slow
speeds. The user has the option to select from three DECEL
FACTOR MODES: AUTO, MANUAL, or OFF.
AUTO: A DECEL FACTOR is automatically maintained
by the controller. It is expressed in inches-per-second-
per-second (In/Sec2) and is used in the Adaptive
Slowdown calculation. The parameter can be
overridden but will change on the next movement.
MANUAL: A DECEL FACTOR may be manually entered
into the MP328 controller. The value is used in the
Adaptive Slowdown calculation. Some trial and error
may be necessary when in the MANUAL mode to find
a DECEL FACTOR which works properly. Ideally, the
machine should shift from fast to slow at some
distance prior to the target long enough so that it
reaches a constant slow velocity before the movement
outputs are turned off.
If the machine tends to shift into slow too soon, increase the DECEL
FACTOR. If the machine tends to shift into slow too late, decrease
the DECEL FACTOR. The DECEL FACTOR should be used in
conjunction with the MINIMUM SLOW DISTANCE to determine the
ideal time to change from fast to slow.
While in the MANUAL mode, the AMS controller will not calculate a
new value for the DECEL FACTOR after each stop.

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OFF: No DECEL FACTOR is used and the controller will
not make an Adaptive Slowdown calculation. The
machine will shift from fast to slow when the
backgauge has reached the MINIMUM SLOW
DISTANCE before the target. For example, if the
MINIMUM SLOW DISTANCE has been set to four
inches, the machine will shift from fast to slow 4 inches
before the programmed position. This may or may not
be enough distance for the machine to decelerate
properly.
The DECEL FACTOR mode defaults to OFF but may be used in
MANUAL or AUTO to increase productivity.
Decel Factor
This parameter is expressed in inches-per-second-per-second
(In/Sec2) and is used in the Adaptive Slowdown calculation
discussed in the DECEL FACTOR MODE above. There is no exact
formula for this value so experimentation is necessary. Ideally the
machine should shift from fast to slow at some distance prior to the
target so that it reaches a constant slow velocity before the
movement outputs are turned off. This value is automatically
calculated by the controller if the DECEL FACTOR MODE is set to
AUTO.
Move Delay
When the RUN input of the MP328 is enabled, there should be a
delay entered before the backgauge starts to move to its new
position. This delay is included for safety purposes and allows for
notification of personnel of the intended move. The delay can be
programmed under the MOVE DELAY parameter. The acceptable
range of this parameter is 0.0 to 5.0 seconds.
New Program Delay
Allows the user to set a delay in the MP328 that will allow the gripper
to continue running its present program for parts that remain in the
machine, even though the XL120 shear controller is starting on a
new type of part. The delay should be set to an amount that will
allow “in process” parts to be completed, but short enough so that
the gripper will start using the new program by the time the newly ran
parts arrive to be processed.
Grip Delay
The GRIP DELAY is a value (in seconds), that can be entered into
the controller to adjust for the gripper hitting the part, and the part
bouncing off of the gripper so that the jaws of the gripper do not grab
the part properly. When the part enters the jaws of the gripper, it will

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activate the gripper so that the jaws will clamp down on the part. A
small delay can be entered, so that the jaws do not close
immediately. The acceptable range of values for this parameter is
0.0 to 5.0 seconds. This is only enable when “Enable Creep Mode”
is set to yes.
Resolution
The RESOLUTION parameter defines the length of the Gripper
movement for each increment of the motor encoder. It is a function
of the distance traveled by the gripper during one revolution of the
motor encoder, and the number of counts per revolution of the motor
encoder. The formula for calculating RESOLUTION is as follows:
Resolution =Distance of Gripper movement
4 x Encoder Count
The encoder used will typically be a motor encoder or an encoder
mounted in such as way as to simulate the motor movement.
Correction
The CORRECTION FACTOR adjusts for errors in the GRIPPER
movement. It is expressed as a percentage, with 100% being no
correction. Increasing the CORRECTION FACTOR causes the
GRIPPER movement to become longer and decreasing the value
shrinks the GRIPPER movement.
Pressing “2” while in the second SETUP screen allows the controller
to perform a calibration of the machine automatically. See section of
manual entitled “Referencing” in the OPERATING PROCEDURE. If
you enter a calibration value, the machine will first move to the
HOME SWITCH, then it will move to the calibration point, and then
prompt the operator for a measured value to that point. The
machine will then calculate the correction value and ask the operator
if they want this value updated. To calculate the new CORRECTION
FACTOR, this formula is used:
New CORR. FACTOR = (Programmed Length Moved ÷Actual
Measured Position Movement) x Old CORR. FACTOR
Filter Constant
The FILTER CONSTANT can be adjusted in order to improve
accuracy. A low value should be used on machines with very stable
line speeds. A high value (greater than 50 Hz) should be used when
rapid fluctuations in line speeds occur. Some trial may be necessary

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to achieve an accurate value. The default value is 32 Hz, which is
considered to be on the high side of the low values. The controller
will allow values from 1.0 Hz to 200.0 Hz.
Units
Length measurements can be programmed and displayed as either
English inches, Metric millimeters, or Metric centimeters. Press any
number key to toggle through the choices.
If “2” is pressed, the INPUT/OUTPUT screen can be viewed. This
can be helpful as a troubleshooting aid if the machine is not working
properly.
Pressing the “Set Up” key will allow you to exit this screen.
Pressing “3” while viewing the SETUP screen enters the
LOCAL/REMOTE function. If the programming for the machine is to
be done with this controller, select the LOCAL mode. If another
controller will program the machine, select REMOTE.
Selecting “4” while viewing the SETUP screen, will cause you to
enter the REFERENCE mode. The machine will immediately locate
the reference switch and then stop. This is done to set a
REFERENCE for the machine. If this is not manually done, it will
automatically find the reference switch when RUN is pressed.
1=Configure 2=In/Out
3=Loc/Remote 4=Reference
In: _ _ _ _ _ _ _ _
Out: _ _ 3 _ _ _ _ _

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Referencing
The controller must be referenced to a known position each time
power is removed and restored to the unit. The fixed reference point
will be a home switch.
Near referencing with a home switch:
1. The MP328 determines the state of the Home Switch.
If the switch is OPEN, skip to step # 3.
2. The MP328 moves the gauge in the forward direction
until the Home Switch is OPEN. It then skips to step #
5.
3. The controller moves the gauge in the reverse
direction until the Home Switch is CLOSED.
4. The MP328 moves the gauge in the forward direction
until the Home Switch is OPEN.
5. At the CLOSED -> OPEN transition of the Home
Switch, the encoder interrupt captures the encoder
count and sets it equal to the reference position.
Far referencing with a home switch:
1. The MP328 determines the state of the Home Switch.
If the switch is OPEN, the controller moves the gauge
in the reverse direction until the Home Switch is
CLOSED.
2. The controller moves the gauge in the forward
direction until the Home Switch is OPEN.
3. The MP328 moves the gauge in the reverse direction
until the Home Switch is CLOSED.
4. At the OPEN -> CLOSED transition of the Home
Switch, the encoder interrupt captures the encoder
count and sets it equal to the reference position.
NOTES:
•If near referencing is used, the home switch must
be wired N/C (normally closed). Far referencing
requires that normally open contacts be used.

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If the “Set Up” key is pressed twice, the following screen appears:
While in the second SETUP screen, pressing “1” will test the
communications with another controller if they are interfaced
together. If there is no communications, the messages “No Data
Received” and “No Data Sent” will be seen.
Pressing “2” while in the second SETUP screen allows the controller
to perform a calibration of the machine automatically. If you enter a
calibration value, the machine will move to that point and prompt the
operator for a measured value to that point. The machine will then
calculate the correction value and ask the operator if they want this
value updated.
(THIS MAY CHANGE!!)
1= Test Communications
2=Auto Calibrate

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Program Mode
The program mode is entered by pressing the “PRG” key. The part
“type” will start to flash, indicating that the controller is waiting for the
entry of the new type of part that is to be made. The operator need
only to press any number key to toggle through the choices, and
press the “ENT” key to lock the selection in., the choices are:
-Single Piece. Only the lip is bent, if programmed.
LL-Shaped. Two bends are made (including the lip).
UU-Shaped. Three bends (including the lip).
0Full wrapper. One piece is made that is bent four
times (with the lip), to form a complete section of duct.
After the TYPE is selected, the HEIGHT and WIDTH measurements
can then be entered. Again use the “ENT” key to lock the selection
in. Only height will be used for (-) type parts.
PROGRAM SCREEN
After the part is programmed, the STATUS screen will be shown,
listing the line velocity, whether the controller is in the LOCAL or
REMOTE mode, the current bend that is being made, the current
position, the part TYPE, and the part dimensions.
STATUS SCREEN
S 0 Loc Bnd 0/3 0.00”
Type : 0 50.00” x 35.00”
Type Height Width
-- 0.00” 0.00”

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Run Operation
With this style of machine, the gripper has a sheet detect switch.
When the run button is first pressed, and there is no sheet in the
gripper, the controller should move the gripper in until the sheet is
found, and engage the gripper. When the run button is pressed and
a sheet is detected by the gripper, the controller should grip the
metal, if it has not already, position to the first bend, engage the
brake (wait for the dwell time), then move to the next position. When
all bends are made, it should return to the clearance position (as
programmed in the configuration).
When part information is programmed, and the RUN button is
pressed the gripper will try to find the part in the forward direction.
As long as the programmed part is shorter than the clearance
position, the part will be processed. If the part is physically longer
than the clearance position, the gripper must be jogged back to allow
the part to be accepted. This must be done on the first part of that
length, and the machine will readjust itself for the remaining parts.
Gripper
Brake
Sheet

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If “metal flow” is set to NORMAL, the home position will be at the
total sheet size plus the clearance distance. If it is REVERSE, then
the home position is at the clearance distance only. In the first case,
the operator will be placing a sheet on a transfer table in front of the
brake. The clearance position of the gripper should be far enough
away so that it will not interfere with the operator putting the sheet on
the table. In the second case, the sheet is fed from the other side of
the brake into the gripper. As soon as the gripper “sees” the metal, it
clamps. Because of this arrangement, it is necessary to feed the
metal only a short distance.
Move to the home
position
New Program
Done
Run
Move in until
switch is on or at
end of the table
Is the gripper
switch on?
No
Engage gripper
Done
Engage gripper
Move to the next
position
Turn the brake on
Wait for dwell dn
Turn the brake off
Wait for dwell up
Last move?
Move to home
Done
Yes
No

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MP328 Switch Settings
Switch Description
1 Unit ID must be OFF
2 Unit ID must be ON
3 Unit ID must be ON
4 Single Speed = OFF / Dual Speed = ON
5 Encoder Direction: CW = OFF / CCW = ON
6 Not Used:Must be OFF
7 Unit ID must be OFF
The proper Unit ID switch setting for the MP328 is: Switches 2 & 3
ON, Switches 1 & 7 OFF.
MP328 Inputs/Outputs
Inputs Description
1 Jog Forward
2 Jog Reverse
3 Home
4 Run Enable
5 Setup/Lockout
6 External Cycle / Manual Reset
7 Sheet Detect
8 Sequence Initiate
Outputs Description
1 Fast/Forward
2 Slow
3 Reverse
4 Run
5 Leaf Up
6 Short Sheet
7 Gripper
8 Brake Down