NTM EZ-Counter User manual

OPERATION and MAINTENANCE MANUAL
www.NewTechMachinery.com
EZ-Counter
Controller
For Gutter Machines and
the SSR Roof Panel Machine

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Table of Contents
Features/Specifications ....................................................................................................... 2
Home................................................................................................................................... 3
Manual Operation: ...................................................................................................... 4
Reset:........................................................................................................................... 4
Job Entry:............................................................................................................................ 4
Miters: ......................................................................................................................... 4
Run:..................................................................................................................................... 6
Compensation: ............................................................................................................ 6
Settings: .............................................................................................................................. 7
Calibration: ................................................................................................................. 7
Units:........................................................................................................................... 8
Clear Jobs:................................................................................................................... 9
Screen:......................................................................................................................... 9
Totalizer: ................................................................................................................... 10
Security: .................................................................................................................... 10
Other: ........................................................................................................................ 11
Encoder Adjustment ......................................................................................................... 12
EZ-Counter Screens.......................................................................................................... 13
Notes: ................................................................................................................................ 14

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Table of Figures
Figure 1: EZ-Counter on Mach II Machine ..................................................................... 1
Figure 2: Home Screen (ft/in.) ......................................................................................... 3
Figure 3: Home Screen (in.)............................................................................................. 3
Figure 4: Home Screen (cm)............................................................................................ 3
Figure 5: Error - Invalid Fraction.................................................................................... 4
Figure 6: (1) 45° Miter..................................................................................................... 5
Figure 7: (2) 45° Miters ................................................................................................... 5
Figure 8: (1) 10° Miter..................................................................................................... 5
Figure 9: Miters Screen.................................................................................................... 5
Figure 10: Miter Default Length Screen............................................................................ 6
Figure 11: Error - Over Length.......................................................................................... 6
Figure 12: Settings – Main Screen..................................................................................... 7
Figure 13: Calibration Screen ............................................................................................ 7
Figure 14: Calibration Length Input Screen ...................................................................... 8
Figure 15: Settings - Units ................................................................................................. 9
Figure 16: Settings - Clear Jobs......................................................................................... 9
Figure 17: Settings – Screen .............................................................................................. 9
Figure 18: Settings – Totalizer......................................................................................... 10
Figure 19: Enter Password ............................................................................................... 10
Figure 20: Settings – Security.......................................................................................... 11
Figure 21: Encoder Adjustment ....................................................................................... 12
Figure 22: Screen Flowchart............................................................................................ 13

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Figure 1: EZ-Counter on Mach II Machine

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Features/Specifications
Protective Carrying Case
Impact resistant, waterproof, crushproof, dustproof and securely padlocked
Easy-Touch Swivel Screen Operation with Adjustable
Brightness
Easily view settings and operations at all times of the day; even before the sun is up!
Program up to 50 Jobs or Lengths
EZ-Counter enables user to input multiple jobs and material lengths
Calibrate on the Fly
Calibrate using a part run from a programmed job to save coil
Track Material
2 Tracking functions: Master counter for lifetime of jobs; counter with optional
daily reset
Integrated Coil Length Calculator
Measure the coil dimensions and calculate the approximate length
Help and Error Screens
On-screen guidance makes navigation and operation effortless

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Home
When the controller is turned on, after going through the startup screens, it
will automatically go to the home screen. Note: After 30 minutes of
inactivity the controller will power itself down.
Overview:
The controller is able to store (5 ) different lengths, designated by “Job”.
The length is programmed in the upper section of the Home Screen. The
Miters button/light will indicate if any miters are programmed for that
job/length. The Run button will start the machine and will run until the
programmed length is met. The bottom section of the Home Screen
displays the current position which can be set back to zero by pressing the
Reset button. The F and R buttons will jog the machine Forward and
Reverse.
Figure 2: Home Screen ft/in.)
Figure 3: Home Screen in.)
Figure 4: Home Screen cm)

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Manual Operation:
The machine can be manually operated from the home screen by pressing
the F and R buttons to make the machine jog Forward or Reverse.
Reset:
Press the Reset button to reset the length counter after shearing the
material. If a programmed job is run, the Current Position will
automatically reset.
Job Entry:
Jobs (or lengths) can be programmed into the controller. The machine
will run until the specified length is reached and the controller will stop
the machine. The controller can store up to fifty jobs or different lengths.
Input the length of the part to be made and press Run to run the part or
press the Up and Down buttons to input another job.
The Job Number display is also an input field. To skip many jobs without
having to press the Up and Down buttons, press the Job Number display
and enter the desired job number to program or run.
When using Imperial units (ft/in. & in.), any length with a valid fraction
can be entered. If the fraction entered is invalid with a “0” in the
numerator or denominator, an invalid fraction screen will popup if the job
is attempted to be run.
Figure 5: Error - Invalid Fraction
Miters:
If the part to be run will be cut on the ends to make a miter, the extra
length needed to cut the miter(s) can be added automatically.
Example:

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Figure 6: (1) 45° Miter
Figure 7: (2) 45° Miters
Figure 8: (1) 10° Miter
Input the length “L” and press the Miters button to access the Miters
screen.
Figure 9: Miters Screen
Press the 0, 1, or 2 buttons on the left to specify the number of miters on
the part. The miter length will automatically populate to the default
length. The length of each miter can be adjusted if needed. For example,
the length for the 10° miter (Figure 8) will be shorter than the 45° miter
(Figure 6).

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Press the Default button to adjust the length of the default miter. For
example, if the controller is on a 5 in. gutter machine, the default miter
length should be less than the default length on a 6 in. gutter machine.
Figure 10: Miter Default Length Screen
Run:
Program the length to be run. The length must be at least 6 in. or 15 cm.
If the Current Position is more than the programmed length, a length error
screen will pop up.
Figure 11: Error - Over Length
Follow the directions on the screen to continue. Shear the part, press
Reset to reset the counter and then proceed with running the programmed
length.
Compensation:
After the power to the motor is cut off, the machine will “coast” to a stop
due to the momentum in all the moving parts. This coasting distance is
typically small and the controller will automatically adjust and
compensate as necessary. The coasting distance will be different for every
machine, different for each material and thickness. The controller will
shut off the motor but will continue to monitor the distance that the
machine coasts. If the machine coasts too far, then the controller will shut
off the motor earlier. If the machine doesn’t coast long enough, the
controller will run the motor slightly longer. In order to prevent over

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compensating, the controller will only adjust the coasting distance by
small increments.
When changing materials or switching to a new large coil it is
recommended to produce (3) 12 in parts in order to allow the controller to
adjust the coasting distance. An alternative, in order to reduce scrap
material, program and run the length needed but measure the part and
adjust the length with the Forward and Reverse job buttons if necessary
BEFORE cutting the piece. The controller should be producing accurate
parts within (3) run and stop cycles and in most cases none of the above
steps will be necessary.
If the machine is consistently making parts too short or too long, use the
Calibration feature in the next section.
Settings:
From the Home screen, press the settings button to access the controller
settings.
Figure 12: Settings – Main Screen
Calibration:
The controller can be calibrated at any time to improve accuracy of the
parts being run. If the machine is consistently making parts too short or
too long, use the Calibration feature. From the Settings screen, press the
Calibration button to access the Calibration screen.
Figure 13: Calibration Screen
On the calibration screen, enter in the desired part length to use to
calibrate the controller. A length of over 12 in. is required and a length of

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36 in. or more is recommended. Press the Run button to run the
calibration part. The machine will run the part and automatically switch to
a screen where the measured length can be input.
Figure 14: Calibration Length Input Screen
The controller will display the theoretical length of the part after it is
produced as the Current Position. The theoretical length may be slightly
different than the intended calibration length. Measure the length of the
part and input the length in the Actual Length fields. Press OK to re-
calibrate the controller or Cancel to return to the Home screen without
making any changes to the controller.
In order to prevent over-calibrating the controller, there is a limit on how
much of a change the calibration can make to the calculations in the
controller. If the measured input length is drastically different than the
theoretical length, a maximum change will be used. If the controller
continues to run panels that are either too long or too short, then initiating
the calibration sequence again may be necessary.
Units:
From the Settings screen, press the Units button to change the type of units
used on the controller for length. Note: Changing the units of measure
will clear all of the jobs that have been programmed. Press Back without
pressing any of the units buttons to avoid clearing the jobs.
Example:
Feet: 10 ft 4 1/16 in
Inch: 124 1/16 in
Centimeter: 315.1 cm

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Figure 15: Settings - Units
Clear Jobs:
From the Settings screen, press the Clear Jobs button to go to the clear
jobs screen. Press the Clear button to clear all the programmed jobs. This
will set all lengths back to 0 and clear all miters. Press Cancel to prevent
clearing the jobs.
Figure 16: Settings - Clear Jobs
Screen:
From the Settings screen, press the Screen button to adjust the Brightness
of the screen or to turn the sound on or off. The brightness of the display
can be adjusted up or down by pressing the right and left arrow buttons.
Figure 17: Settings – Screen

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Totalizer:
From the Settings screen, press the Totalizer button to view and reset the
total length counter. This counter is not password protected and can be
reset at any time.
Figure 18: Settings – Totalizer
Security:
From the Settings screen, press the Security button to access the security
settings and password protected length counter. This section is useful if
the owner of the machine suspects a crew is running more material than
expected. For this feature to be effective, the manual start buttons must be
disabled in the contactor box, See drawing: EZC-G (gutter machines) or
EZC-P (SSR machines).
If the password is set to “0”, no password will be required to access the
security screen. If the password is set to anything except “0”, a password
will need to be entered to access the security screen.
Figure 19: Enter Password
The total counter will track the length of coil that goes through the
machine as long as the encoder is reading the material. If the encoder has
been disconnect or disabled, the controller will track the amount of time
when the encoder is not reading material but the machine is being jogged
forward from the controller (not the manual push buttons). Press the
Change PW button to change the password.

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Figure 20: Settings – Security
Other:
From the Settings screen, press the Other button to view miscellaneous
values that are programmed into the Controller. These values are not
adjustable from this screen.
Counts: Encoder counts per revolution of the encoder wheel
Circum: Encoder wheel circumference (this value changes when the
controller is calibrated. The factory value is 6.0000 in.
Kerf: This is the thickness of the shear blade. When the length counter is
reset, it will reset to this value. The machine must be run this length to
clear the exit end of the shear blade.
Stop Rxn: This is the distance (in inches) that the machine coasts after
the run cycle is shut off. The machine will coast a longer distance with
thinner materials compared to thicker materials. Each machine will coast
a different length. This value will change automatically as needed.

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Encoder Adjustment
The encoder should have tension on the material in order to track the
material accurately. To check the tension on the encoder, gently lift up on
the wheel. The encoder should be able to be lifted 1/8” – 1/4" from the
surface of the material. If the encoder does not spring back down into
position, adjustment may be necessary. The encoder is difficult to adjust
in the machine. It is recommended to remove the encoder with the
mounting block, set the tension and reinstall.
After removing the encoder from the machine remove the rubber cap on
the back of the encoder. Loosen the 3/32” set screw found under the
rubber cap. Lay the assembly on the following diagram and rotate the
encoder so that the angle matches the diagram. Tighten the 3/32” set
screw. Replace the rubber cap and reinstall the assembly into the machine.
Check the tension on the encoder by pulling the wheel away from the stop
plate. If the encoder does not have sufficient tension, remove the
assembly and adjust the tension as necessary.
Figure 21: Encoder Adjustment

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EZ-Counter Screens
Figure 22: Screen Flowchart

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Notes:

16265 E. 33rd Dr. Ste 40 | Aurora, CO 80011
EZC-MAN | Revision 2 | 01-28-2021