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.

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Open Loop Feed-to-Stop, Shear-Only
Feed-to-stop machines stop the material for each press operation and the die
remains at a fixed location. A simple feed-to-stop machine is shown in Figure 2.
ENCODER
CUTOFF
Material Flow
FEED SYSTEM
Figure 2: Feed-to-Stop Machine with Cutoff
Typical Operation
1. Material is fed to the cutoff press.
2. The cutoff press is fired to reference the material’s position.
3. The controller is put into RUN to set the machine into motion.
4. The encoder reports the material motion to the controller.
5. The controller halts the material at the programmed locations.
6. The controller fires the cutoff press at the programmed locations.
7. Controller puts material back into motion to continue production.
8. The controller halts the machine motion at the end of the job, or as
programmed by the relevant setup parameters.

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Chapter 3: Model Customization
Software Models
The XL200 Series controller is factory-programmed with a specific software
model. Hundreds of different software models are available to handle the large
variety of machine types found throughout the roll forming industry. Additionally
each individual software model may be configured to operate in one of several
different modes, depending on the machine’s requirements. Some model
configurations may require unique input and output definitions to handle a
particular machine type.
The factors that influence which software model should be selected and how it
should be configured for a particular application include:
•The number of presses on the machine that the XL200 Series controller must
control.
•Whether the machine operates in a flying-cut or feed-to-stop mode.
•The presence of selectable or gagged tooling on one or more presses.
•The presence of a sensor that detects pre-punched holes on the part.
•The presence of one or more peripheral devices that the XL200 Series
controller interfaces with.

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Model Types and Options
The following tables provide configuration instructions for each software model
in each operating mode. Input and output definitions are provided for each model
type are also listed.
Model Types
Model
Type Description Switch Settings I/O Definitions
XL200 Shear and 1 punch controller, single or two-
speed operation, feed-to-stop or flying-cut
(& punch), shear/punch boost outputs
available.
XL202 Shear and 1 punch (or gag), single or two-
speed operation, feed-to-stop or flying-cut
(& punch).
XL206 Shear and up to 5 punches (or gags), single
or two-speed operation, feed-to-stop or
flying-cut (& all punches).
XL212 Shear and up to 11 punches (or gags), single
or two-speed operation, feed-to-stop or
flying-cut (& all punches).
XL200H Hole-Detecting controller, shear only,
flying-cut, single or two-speed operation.
XL202H Hole-Detecting controller, shear with one
gagged punch tool, flying-cut, single or
two-speed operation.
XL206H Hole-Detecting controller, shear with up to
5 gagged punch tools, flying-cut, single or
two-speed operation.
XL212H Hole-Detecting controller, shear with up to
11 gagged punch tools, flying-cut, single or
two-speed operation.
XL266 Shear and up to 5 punch presses, two-speed
operation, feed-to-stop only.

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Model Options
Model Option Description
Expanded Gag Board (E) Allows the XL200 Series controller to
communicate with up to 4 additional output cards
for controlling machines with a large number of
gagged punch tools. This option is only available
for model type XL212. See the XL200 Series
Auxiliary Devices manual for more details.
Print on Part (P) Allows the XL200 Series controller to
communicate with an industrial printer used for
part marking. This option is available for most
model types. See the XL200 Series Auxiliary
Devices manual for more details.
Bundle Print (B) Allows the XL200 Series controller to
communicate with an industrial printer used for
bundle ticket printing. This option is available for
most model types. See the XL200 Series Auxiliary
Devices manual for more details.
Extended Macro (M) Allows the user to create and store additional
Macro Patterns, more than are available in the
standard software model. This option is available
for most model types. See the XL200 Series
Operator’s Guide for more details on programming
punch patterns and macro patterns.
Auxiliary Controller (S) Allows the XL200 Series controller to
communicate with one or more auxiliary (slave)
controllers. This option may be required for
complex shear & punch machines requiring more
than one AMS Controls controller. This option is
available for most model types. See the XL200
Series Auxiliary Devices manual for more details.
Analog Speed Logic (AA) Enables the XL200 Series controller’s analog
output port and provides additional setup
parameters. An analog voltage is provided by the
controller that can be used to control the roll
forming machinery’s fast and slow speeds
proportional to the current part length. This option
is available for most model types.

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Model Option Description
Alternating Press (L) Allows the XL200 Series controller to control two
punch presses in an alternating fashion. The
controller is programmed as if there is only one
punch press, but automatically alternates targets
between two physical presses to provide increased
production rates. This option is only available for
Model Type XL200.
Multi-Axis (X) Enables additional fields in the XL200 Series
controller’s user interface and allows the controller
to communicate with other control devices. The
intended application for this model option is a
machine that includes the capability to re-position
machine elements (punch tooling or roll form
tooling) based on additional data entered into the
XL200 Series controller. This option is available
for most model types. See the XL200 Series
Auxiliary Devices manual for more details.
PLC Interface (I) Allows the XL200 Series controller to
communicate with a PLC using the industry-
standard MODBUS interface. Several additional
features are available when this option is enabled
including controlling PLC inputs and outputs,
displaying PLC diagnostics messages on the
XL200 Series controller screen, and publishing
high-level run-time data from the controller to the
PLC. This option is available for most model
types. See the XL200 Series Auxiliary Devices
manual for more details.
Combining Model Options
Several model options may be combined together as long as their functionality
does not conflict with each other. Some examples of XL200 Series controller
software model names are:
•XL200BP – XL200 model type with the Bundle Print and Print on Part model
options enabled.
•XL206XI – XL206 model type with the Multi-Axis and PLC Interface options
enabled.

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•XL212AABEMS – XL212 model type with the Analog Speed Logic, Bundle
Printer, Expanded Gag, Extended Macro, and Auxiliary Controller options
enabled.
Configuration Switch Settings
Each model type must be configured for one of several different operating modes,
depending on the machine’s requirements. This is done by setting the controller’s
configuration dip-switches located on the top panel of the enclosure. There are 10
switches provided, each one can be set to On or Off. The operating functionality
determined by these switches varies depending on the controller’s model type.
The following tables define how the configuration dip-switches are used for each
model type.
Model Types: XL200 & XL200H
Switch
# Off On
1 Material stops for each Shear
(cut) operation Material does NOT stop for each shear (cut) operation
2 Output provided for Shear Die
Boost functionality Output provided for Shear Up functionality
3 Machine does NOT shift into a
slow speed prior to each shear
(cut) operation
Machine DOES shift into a
slow speed prior to each shear
(cut) operation
4 Auto-Crop functionality is
DISABLED Auto-Crop functionality is ENABLED (for machines that
are incapable of performing a
stationary cut)
5 Material stops for each punch
operation Material does NOT stop for each punch operation
6 Output provided for Punch Die
Boost functionality Output provided for Punch Up functionality
7 Machine does NOT shift into a
slow speed prior to each punch
operation
Machine DOES shift into a
slow speed prior to each
punch operation
8 Reserved –Set to Off Reserved –Set to Off
9 SVGA Monitor DISABLED SVGA Monitor ENABLED
10 Reserved –Set to Off Reserved –Set to Off

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Notes:
-The Shear Boost functionality can not be enabled for a feed-to-stop
shear. The Punch Boost functionality can not be enabled for feed-to-
stop punch press.
-The Auto-Crop functionality is only available for model type XL200
and can not be enabled when the controller is configured for a punch
press.
-Turning off switches 5, 6, and 7 completely disables the punch press
functionality.
-Model Type XL200H can not be configured with a punch press and
can not be configured to operate in a feed-to-stop mode.
-If no external SVGA monitor is connected, switch 9 should be turned
off to improve the appearance of the liquid crystal display.
Model Types: XL202, XL206, XL212, XL202H, XL206H, &
XL212H
Switch # Off On
1 Material stops for each
Shear (& punch) operation Material does NOT stop for each shear (& punch)
operation
2 Reserved –Set to Off Reserved –Set to Off
3 Machine does NOT shift
into a slow speed prior to
each shear (& punch)
operation
Machine DOES shift into a
slow speed prior to each shear
(& punch) operation
8 Reserved –Set to Off Reserved –Set to Off
9 SVGA Monitor DISABLED SVGA Monitor ENABLED
10 Reserved –Set to Off Reserved –Set to Off

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Switch #4 Switch #5 Switch #6 Switch #7
Total Number
of Presses
(including the
shear)
Off Off Off Off 1
On Off Off Off 2
Off On Off Off 3
On On Off Off 4
Off Off On Off 5
On Off On Off 6
Off On On Off 7
On On On Off 8
Off Off Off On 9
On Off Off On 10
Off On Off On 11
On On Off On 12
Notes:
-Model Types XL202H, XL206H, and XL212H can not be configured
with any punch presses and can not be configured to operate in a feed-
to-stop mode.
-The maximum number of press and/or gag outputs available for each
model type is specified by the last two digits of the model type number
(XL202 – 2 outputs, XL206 – 6 outputs, XL212 – 12 outputs). For
example: If model type XL206 is configured for a machine with 2
presses (switch #4 On), The XL200 Series controller provides outputs
for the shear press, one punch press, and four gagged tools.
-The Shear Boost functionality can not be enabled for a feed-to-stop
shear. The Punch Boost functionality can not be enabled for feed-to-
stop punch presses.
-Turning off switches 5, 6, and 7 completely disables the functionality
or all seven punch presses.
-If no external SVGA monitor is connected, switch 9 should be turned
off to improve the appearance of the liquid crystal display.

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Model Type: XL266
Switch # Off On
4 Reserved –Set to Off Reserved –Set to Off
5 Reserved –Set to Off Reserved –Set to Off
6 Reserved –Set to Off Reserved –Set to Off
7 Reserved –Set to Off Reserved –Set to Off
8 Reserved –Set to Off Reserved –Set to Off
9 SVGA Monitor DISABLED SVGA Monitor ENABLED
10 Reserved –Set to Off Reserved –Set to Off
Switch #1 Switch #2 Switch #3 Total Number of Presses
(including the shear)
Off Off Off 1
On Off Off 2
Off On Off 3
On On Off 4
Off Off On 5
On Off On 6
Notes:
-The total number or presses on the machine includes the exit shear.
-Turning switches 1, 2, and 3 off slows for shear-only operation.
-To enable the entry shear option, the controller must be configured for
two or more presses.
-The XL266 model type does not support gagged presses or die boosts.
-If no external SVGA monitor is connected, switch 9 should be turned
off to improve the appearance of the liquid crystal display.

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Input/Output Definitions
Only after the XL200 Series controller’s software model is identified and the
configuration dip-switches have been set, the definitions for all inputs and outputs
are known. The following tables define how the configuration dip-switches are
used for each model type. A description for how each input and output functions
is provided in a later chapter.
Model Types: XL200 & XL200H
I/O # Inputs Outputs
1 Jog Forward Fast
2 Jog Reverse Slow
3 Run Reverse
4 Reserved Run
5 Setup Lockout Item Complete
6 Manual Shear Forward
7 Manual Punch Reserved
8 Tail Out / Sheet Detect Part Print Trigger
9 Press 0 (Shear) Complete Press 0 (Shear) Down
10 Press 1 (Punch) Complete Press 1 (Punch) Down
11 Reserved Press 0 (Shear) Up/ Boost
12 Reserved Press 1 (Punch) Up/ Boost
13 Reserved Reserved
14 Reserved Reserved
15 Reserved Reserved
16 Reserved Reserved
17 Reserved Reserved
18 Reserved Reserved
19 Reserved Reserved
20 Reserved Reserved
21 Asynchronous Print Detect Not Used
22 Manual Stacker Stacker
23 Reserved Reserved