AMS XL200 Series Use and care manual

XL200 Series Open Loop Controller
Version 3.18
Installation Guide &
Technical Reference

XL200 Series OL Controller Installation Guide & Technical Reference
Copyright ©2007 −AMS Controls, Inc. All rights reserved.
The information contained in this document is proprietary to AMS Controls, Inc., and is not to
be 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 described in this handbook must be performed only by
trained, certified industrial electricians in accordance with local, state, federal, and NEC codes
and regulations. While AMS Controls has taken all reasonable care to develop safe procedures,
it accepts no responsibility 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 available at: www.amscontrols.com/files/manuals
AMS Controls, Inc.
12180 Prichard Farm Road
Maryland Heights, MO 63043
314.344.3144 – 1-800-334-5213 (US & Canada) – fax: [phone] – [email protected]
www.amscontrols.com

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Table of Contents
CHAPTER 1: INSTALLATION OVERVIEW .......................................................................1
CHAPTER 2: SYSTEM TYPE DESCRIPTION.....................................................................3
OVERVIEW...................................................................................................................................3
Open Loop Flying Cutoff with Flying Punch Press.................................................................4
Open Loop Feed-to-Stop, Shear-Only .....................................................................................5
CHAPTER 3: MODEL CUSTOMIZATION...........................................................................6
SOFTWARE MODELS....................................................................................................................6
Model Types and Options ........................................................................................................7
CONFIGURATION SWITCH SETTINGS........................................................................................10
Model Types: XL200 & XL200H ...........................................................................................10
Model Types: XL202, XL206, XL212, XL202H, XL206H, & XL212H..................................11
Model Type: XL266................................................................................................................13
INPUT/OUTPUT DEFINITIONS....................................................................................................14
Model Types: XL200 & XL200H ...........................................................................................14
Model Type: XL200L (Alternating Punch Option Enabled)..................................................16
Model Types: XL202 & XL202H ...........................................................................................17
Model Types: XL206 & XL206H ...........................................................................................19
Model Types: XL212 & XL212H ...........................................................................................21
Model Type: XL200DLP (with the Alternating Punch & Print on Part Options Enabled)...23
Model Type: XL266................................................................................................................24
CHAPTER 4: HARDWARE & INSTALLATION ...............................................................26
GENERAL INFORMATION...........................................................................................................26
HARDWARE CONFIGURATION &CONNECTIONS......................................................................26
Back Panel Connections........................................................................................................28
Additional Connections..........................................................................................................29
POWER REQUIREMENTS............................................................................................................30
ELECTRICAL INTERFACE ..........................................................................................................30
ENCODER INSTALLATION..........................................................................................................31
CHAPTER 5: INPUT & OUTPUT DESCRIPTIONS..........................................................35
INPUTS........................................................................................................................................35
Jog Forward...........................................................................................................................35
Jog Reverse............................................................................................................................35
Run.........................................................................................................................................35
Shear Complete......................................................................................................................36
Shear Up Complete................................................................................................................36
Setup Lockout.........................................................................................................................36
Manual Shear.........................................................................................................................36
Manual Punch........................................................................................................................37
Coil Tail-out (Sheet Detect)...................................................................................................37
Press (n) Complete.................................................................................................................37
Press (n) Up Complete...........................................................................................................38
Manual Stacker......................................................................................................................38

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Asynchronous Print Detect....................................................................................................38
Hole Detect ............................................................................................................................38
OUTPUTS....................................................................................................................................39
Fast, Slow, Reverse, and Forward.........................................................................................39
Run.........................................................................................................................................39
Shear/Press Down..................................................................................................................39
Shear/Press Up ......................................................................................................................40
Shear/Press Die Boost ...........................................................................................................40
Item Complete........................................................................................................................40
Stacker....................................................................................................................................40
SIGNAL PORTS...........................................................................................................................41
Analog Output #1 (Proportional to Line Velocity)................................................................41
Analog Output #2 (Analog Speed Logic)...............................................................................41
Comm. Port “A” (RS485 Eclipse Port).................................................................................41
Comm. Port “B” (RS485 Auxiliary Port)..............................................................................41
Comm. Port “C” (RS422 High Speed Port)..........................................................................41
Comm. Port “D” (RS422 High Speed Port)..........................................................................42
CHAPTER 6: SETUP PARAMETERS..................................................................................43
SETUP SCREEN...........................................................................................................................43
MACHINE PARAMETERS MENU ................................................................................................44
Press Data..............................................................................................................................44
Shear Boost Dwell..................................................................................................................45
Run Mode Options .................................................................................................................50
Machine Layout .....................................................................................................................62
Hole Detect Options...............................................................................................................67
Advanced Setup......................................................................................................................69
Trim Correction.....................................................................................................................73
CONTROLLER SETTINGS ...........................................................................................................74
Clock / Calendar....................................................................................................................75
Network Settings ....................................................................................................................76
PLC Communication..............................................................................................................79
Operator Preferences.............................................................................................................81
Quickset Data.........................................................................................................................84
CHAPTER 7: TOOL DATA....................................................................................................87
TOOLING TERMS .......................................................................................................................87
WHAT IS TOOL DATA................................................................................................................87
DETERMINING THE MACHINE ZERO REFERENCE POINT ........................................................88
DEFINING A TOOL .....................................................................................................................89
NESTED TOOLING......................................................................................................................91
CHAPTER 8: STARTUP AND CALIBRATION..................................................................94
INITIAL TESTS AND SETTINGS...................................................................................................94
Wiring Verification ................................................................................................................94
Model Customization.............................................................................................................95
Initial Setup Parameters........................................................................................................95
TEST THE E-STOP CIRCUIT .....................................................................................................100

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TEST INPUTS AND OUTPUTS....................................................................................................100
Test Jog outputs ...................................................................................................................100
Test Encoder Direction........................................................................................................101
Test Shear Outputs...............................................................................................................101
Initial Run & Calibration.....................................................................................................101
FLYING CUTOFF CALIBRATION ..............................................................................................102
What is Shear Reaction?......................................................................................................102
Setting Shear and Boost Reaction Times.............................................................................104
FEED-TO-STOP SETUP .............................................................................................................110
Minimum Slow Distance (2-speed lines only)......................................................................110
Deceleration Mode (2-speed lines only)..............................................................................111
Tolerance .............................................................................................................................113
Stopping Mode.....................................................................................................................114
Stopping Reaction................................................................................................................114
Inducing Automatic Values..................................................................................................117
TRIM CORRECTION .................................................................................................................118
APPENDIX A: SPECIFICATIONS........................................................................................121
MECHANICAL SPECIFICATIONS ..............................................................................................121
ELECTRICAL SPECIFICATIONS................................................................................................122
APPENDIX B: DIAGRAMS ...................................................................................................125
WIRING DIAGRAMS.................................................................................................................125
APPENDIX C: WORKSHEETS FOR USER-RECORDED PARAMETERS...................129
CONTROLLER INFORMATION..................................................................................................129
MACHINE PARAMETERS SHEET..............................................................................................130
TOOL DATA SHEET..................................................................................................................137
PATTERNS SHEET ....................................................................................................................139

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Chapter 1: Installation Overview
When installing an XL 200OL controller, you must have certain specific
information available concerning the controller and your line. Once you have that
information, you can install the controller following the procedures outlined in
this guide.
The following steps offer a high-level “bird’s-eye” view of the installation
process. The location for further, detailed information is included for each step.
aWarning: It is essential that the controller be configured and installed
properly -- Improper installation or configuration can result in damage to
the system!
1. Determine your application type (see “System Type Description” page 1).
2. Determine the appropriate software model for your application (see
“Software Models” page 6.)
3. Configure the controller model to your specific application (see
“Configuration Switch Settings” page 10).
4. Install the hardware and perform all wiring (see “Hardware & Installation”
page 26).
5. Apply power, then set system parameters (see “Setup Parameters” page 43)
and enter tool data (see “Tool Data”, page 87).
6. Calibrate the system (see “Startup and Calibration” page 94).

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Chapter 2: System Type
Description
Overview
The AMS ControlsXL200 Series controller is a computerized device used to
control roll forming machinery in production, including:
•Controlling the material movement through the machine.
•Measuring the amount of material moving past all the presses.
•Cycling the punch presses at programmed points.
•Cycling the cutoff press at the programmed length.
•Stopping the machine when the correct numbers of parts are produced.
•Alerting the operator of procedure errors and machine malfunctions.
•Providing built-in help messages and diagnostics.
•Changing part lengths on the fly.
•Programming in finished part dimensions.
•Tracking of completed productivity, downtime, scrap, coil consumption,
operating efficiencies, and more.
•Providing production data reporting—coil inventory, and good/scrap footage.
Categories
There are two basic categories of roll forming machines:
•Feed-to-stop machines, where material stops for each press operation and the
cutoff or punching die remains stationary relative to the material.
•Flying cutoff machines, where material does not stop for press operations and
the cutoff or punching die moves with the material during the press cycle.
Combinations
The XL200 Series controller can be configured to operate machines of each type,
as well as numerous variations and combinations. Typical applications include:

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•Open Loop Flying Cutoff with Flying Punch Press
•Open Loop Feed-to-Stop, Shear-Only
Open Loop Flying Cutoff with Flying Punch Press
In a flying die application, the punch press and cutoff move with the material, and
the material is not stopped for press operation. A block diagram of a typical roll
forming operation with a pre-notch and a post-cut is shown in Figure 1.
AMS Controls XL 200 Series
F1
F2
F3
F4
F5
F6
Help
Diagnostics
Inc. Qty
Status
Set Up
Program
Enter
Move
Up
Move
Down Page
Page
Up
Down
Home
INS
End
CE
_
.
78 9
654
12 30
Display
MATERIAL FLOW
ENCODER
CUTOFF
PUNCH
Figure 1: Roll-former with Flying Cutoff & Punch Press
Typical Operation
7. Material is loaded through the entire machine.
8. The cutoff press fires to reference the material’s position.
9. The controller is put into RUN to set the machine into motion.
10. The encoder reports the material motion to the controller.
11. The controller fires the punch and cutoff presses at the programmed location.
12. The controller halts the machine motion at the end of the job, or as
programmed by the relevant setup parameters.