Xl200 Series

XL200 Series Open Loop Controller
Version 3.18
Installation Guide &

Technical Reference
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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: 314.344.9996 – [email protected]
www.amscontrols.com

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 Type: XL200L (Alternating Punch Option Enabled)..................................................16
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

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
ii

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
iii

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.
a Warning: 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).


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:

• 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.
ENCODER
MATERIAL FLOW
PUNCH CUTOFF
AMS Controls XL 200 Series
F1
F2 Display
F3
F4
F5
F6
Help Status
Diagnostics Set Up
Move Page INS _ 7 8 9
Up Up
Inc. Qty Home End . 4 5 6 Program
Move Page CE 0 1 2 3 Enter

Down Down
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.

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.
Material Flow
ENCODER
FEED SYSTEM CUTOFF
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.

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.

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 Switch I/O

Type Description Settings 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
XL212H Hole-Detecting controller, shear with up to
11 gagged punch tools, flying-cut, single or
XL266 Shear and up to 5 punch presses, two-speed
operation, feed-to-stop only.

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.

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
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.

• 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 Material does NOT stop for
(cut) operation each shear (cut) operation
2 Output provided for Shear Die Output provided for Shear Up
Boost functionality functionality
3 Machine does NOT shift into a Machine DOES shift into a
slow speed prior to each shear slow speed prior to each shear
(cut) operation (cut) operation
4 Auto-Crop functionality is Auto-Crop functionality is
DISABLED ENABLED (for machines that
are incapable of performing a
stationary cut)
5 Material stops for each punch Material does NOT stop for
operation each punch operation
6 Output provided for Punch Die Output provided for Punch Up
Boost functionality functionality
7 Machine does NOT shift into a Machine DOES shift into a
slow speed prior to each punch slow speed prior to each
operation punch operation
8 Reserved –Set to Off Reserved –Set to Off
9 SVGA Monitor DISABLED SVGA Monitor ENABLED
10

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 Material does NOT stop for
Shear (& punch) operation each shear (& punch)
operation
3 Machine does NOT shift Machine DOES shift into a
into a slow speed prior to slow speed prior to each shear
each shear (& punch) (& punch) operation
operation
11

Total Number
of Presses
Switch #4 Switch #5 Switch #6 Switch #7 (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.
12

Model Type: XL266

Switch # Off On
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.
13

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.

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
21 Asynchronous Print Detect Not Used
22 Manual Stacker Stacker
14

24 Hole Detect Reserved
Notes:
- Input 21 (Asynchronous Print Detect) and Output 8 (Part Print
Trigger) are only available when the Print on Part model option is
enabled.
- Input 24 (Hole Detect) is only available for model type XL200H.
- All inputs and outputs that pertain to the punch press (press 1) are not
active when the controller’s configuration dip-switches are set to
disable the punch press functionality.
15

Model Type: XL200L

(Alternating Punch Option Enabled)
1 Jog Forward Fast
2 Jog Reverse Slow
3 Run Reverse
4 Reserved Run
11 Press 2 (Punch) Complete Press 2 (2nd Punch) Down
14 Reserved Press 2 (2nd Punch) Up/ Boost
Notes:
enabled.
16

- All inputs and outputs that pertain to the punch press (press 1) are not
active when the controller’s configuration dip-switches are set to
disable the punch press functionality.

1 Jog Forward Fast
2 Jog Reverse Slow
3 Run Reverse
4 Reserved Run
10 Press 1 Complete Press 1 Down | Gag 1
17

Notes:
enabled.
- Output 10 (Press 1 Down | Gag 1) functions as the Press 1 Down
output when the controller is configured for two presses, otherwise it
functions as a gag output.
- Input 10 (Press 1 Complete) is only active when the controller is
configured for two presses.
18


1 Jog Forward Fast
2 Jog Reverse Slow
3 Run Reverse
4 Reserved Run
10 Press 1 Complete Press 1 Down| Gag 1
Notes:
enabled.
19

- The controller will provide as many Press Down outputs as required

based on the number of presses defined by the configuration dip-
switch setting. The remaining outputs will be defined as gags.
- The controller will provide as many Press Complete inputs as required
switch setting. The remaining inputs will be unused.
20


1 Jog Forward Fast
2 Jog Reverse Slow
3 Run Reverse
4 Reserved Run
Notes:
enabled.
21


switch setting. The remaining outputs will be defined as gags.
- The controller will provide as many Press Complete inputs as required
switch setting. The remaining inputs will be unused.
22

Model Type: XL200DLP

(with the Alternating Punch & Print on Part Options
Enabled)
1 Jog Forward Fast
2 Jog Reverse Slow
3 Run Reverse
4 Reserved Run
11 Press 2 (Punch) Complete Press 2 (2nd Punch) Down
14 Reserved Press 2 (2nd Punch) Up/ Boost
21 Manual Press 2 Not Used
23 Asynchronous Print Detect Scanner Verify
24 Reserved Horn
Notes:
- All inputs and outputs that pertain to the punch presses are not active
when the controller’s configuration dip-switches are set to disable the
punch press functionality.
23


enabled.
Model Type: XL266

1 Jog Forward Fast
2 Jog Reverse Slow
3 Run Reverse
4 Manual Press 2 Run
7 Manual Punch 1 Reserved
10 Press 1 Complete Press 1 Down
15 Press 0 (Shear) Up Complete Press 0 (Shear) Up
16 Press 1 Up Complete Press 1 Up
21 Asynchronous Print Detect Reserved
23 Stacker Complete Reserved
Notes:
24


enabled.
switch setting. The remaining outputs will be unused.
- The controller will provide as many Press Complete and Press Up
Complete inputs as required based on the number of presses defined
by the configuration dip-switch setting. The remaining inputs will be
unused.
25

Chapter 4: Hardware &

Installation
General Information
a WARNING! This document is intended for users familiar with electrical
control system wiring, cabinet layout, and component sizing, as well as
local and national electrical codes. 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.
Hardware Configuration & Connections

The XL200 Series controller is available in two hardware configurations:
• Sinking Outputs with Sourcing Inputs (standard) – identified with
green connectors.
• Sourcing Outputs with Sinking Inputs (optional) – identified with
black connectors.
The XL200 Series controller has six 16-pin terminal-style connectors on its back
surface and several additional interface ports on its top surface. Figure 5 through
Figure 6 show the controller’s keypad and display, and the locations of all of the
various connections.
26

Figure 3: XL200 Series Controller - Front View
27

Back Panel Connections
Figure 4: XL200 Series Controller - Back View
The six connectors on the back surface provide the following connection points:
• Connector A - 24VDC CPU Power Supply input, Encoder 1 input, Encoder 2
input.
• Connector B – 24VDC I/O Power Supply input, Analog 1 output, Analog 2
output, Comm. Port-A (RS485), Comm. Port-B (RS485).
28

• Connector C – General Purpose Inputs 1-15.

• Connector D – General Purpose Inputs 16-24, I/O Common, Comm. Port-C
(RS422).
• Connector E – General Purpose Outputs 1-15, I/O Common.
• Connector F – General Purpose Outputs 16-24, I/O Common, Comm. Port-D
(RS422).
• Six user-accessible fuses are provided to protect the controller CPU power
supply and input/output circuits.
Additional Connections
Figure 5: XL200 Series Controller - Top View
The interface ports on top provide the following connection points:

• SVGA Port (15-pin) - for connection to an industry-standard SVGA monitor.
• Scanner/Debugger Port (RS232, 9-pin) - for connection to an AMS-approved
barcode scanner. This port is also used for updating the controller’s firmware
(a laptop computer with the appropriate software application required).
• Mouse – for connection of any industry-standard PS/2 mouse.
• Keyboard – for connection of any industry-standard PS/2 keyboard.
• SERCOS Transmitter/Receive/Power Indicator – for connection to servo
drives and other devices on an industry-standard SERCOS fiber-optic
communications network.
29

Power Requirements
CPU Power Supply
A high-quality, regulated supply is recommended for use with the XL200 Series
controller.
• 24 Volts DC (+/- 10%)
• 2.5 Amps, minimum
I/O Power Supply
A separate, non-regulated power supply is sufficient for the Input/Output supply

voltage.
Note: Power supplies must not be shared—otherwise, there can be no optical

isolation.
This power supply should be properly sized based on the load requirements for all
output devices connected to the XL200 Series controller. Typical output devices
include, motor contactors, relays, and valve solenoids. Each device has its own
power requirements that will determine the size requirements for the I/O power
supply.
Refer to Appendix A. Specifications for all other power requirements.
Electrical Interface
Refer to Figure 28: XL200 Cutout Dimensions (page 122) for the pane cutout
drawing and Appendix A:
30

Diagrams (page 125) for examples of typical XL200 Series controller wiring
diagrams.
Encoder Installation
Mounting the encoder properly is the most important aspect of the XL200 Series
controller installation because accurate material tracking is required for the
controller to produce consistently accurate parts. Here are few guidelines to
consider when installing the material-tracking encoder with an XL200 Series
controller:
Encoder Placement
AMS Controls recommends that the encoder be located in a position where the
material is stable, free from excessive vibration, and not exposed to a large
amount of liquid coolant. The distance from the encoder to the cut-off press must
not fluctuate, and kept as short as possible. Locate the encoder on a flat section of
material where the entire surface of the wheel makes contact with the material;
avoid tracking on curved or arced surfaces.
Whenever possible, the encoder wheel should ride directly on the material. In
some applications where space is limited, extra couplers, belts, or shaft extenders
are required for the encoder wheel to reach the material. Extra care should then be
taken to ensure that no slippage or backlash can occur in the coupling mechanism.
Encoder Mounting and Alignment
The encoder wheel should turn perfectly parallel to the direction of material flow.
The face of the wheel should be mounted at a 90 degree angle from the surface of
the material it is tracking. Figure 6 illustrates several examples of improper
encoder mounting.
31

END VIEW END VIEW

BENT SHAFT
SLIPPAGE
TOO LITTLE PRESSURE TOO MUCH PRESSURE
TOP VIEW
END VIEW
WOBBLE
WHEEL NOT SQUARE

TO MATERIAL
WHEEL NOT PARALLEL TO
MATERIAL FLOW
Figure 6: Improper Encoder Mounting
For best results, the encoder wheel to should be able to float up and down with
the material,
Mount the encoder wheel using a tensioning system (spring tension, pneumatic
pressure, or a weighting device) to apply adjustable and controlled pressure
between the encoder wheel and the material, This way, the encoder wheel can
move with the material’s fluctuations, yet continue to track the surface without
slippage.
Note: 7-10 pounds per square inch of pressure is recommended for proper
material tracking--excessive pressure causes binding in the encoder bearing,
or causes the shaft to bend over time.
Some applications may require special mounting hardware and special types of
tracking wheels. The encoder wheel may need to be mounted onto the surface of a
feed roll or straightener roll, or the encoder itself may need to be mounted onto
the end of a roll. Tracking in this method may provide the desired results, but also
creates potential for slippage between the rolls and the material, costing
accuracy—appropriate precautions must be taken.
32

AMS Controls Encoders, Wheels, & Brackets
AMS Controls provides specially designed encoders, wheels, and mounting

brackets for use with all XL200 Series controllers.
33

Chapter 5: Input & Output

Descriptions
Although the XL200 Series controller’s Input & Output definitions vary based on
the software model and configuration dip-switch settings, their functionality
generally remains consistent.
This chapter lists and describes the valid inputs and outputs.
Inputs
Jog Forward
Jog Forward jogs the material forward through the machine. The XL200 Series
controller ignores this input if it goes active while the controller is in the run
mode. The controller will turn on its Slow and Forward outputs for as long as the
Jog Forward input is activated. This Jog Forward input is typically activated by a
momentary push-button.
Jog Reverse
Jog Reverse jogs the material backward through the machine. The XL200 Series
controller ignores this input if it goes active while the controller is in the run
mode. The controller will turn on its Slow and Reverse outputs for as long as the
Jog Reverse input is activated. The Jog Reverse input is typically activated by a
momentary push-button.
Run
Run causes the XL200 Series controller to enter and exit the run mode. When
activated, the controller enters the run mode as long as valid order data is
programmed and no error conditions are detected (See the XL200 Series
Operator’s guide for more details about entering the Run Mode). The controller
exits the run mode any time this input goes in-active. The Run input is typically
initiated by a momentary push-button, but is latched-in (maintained) by a control
relay tied to the controller’s Run Output.
35

Shear Complete
The Shear Complete is an input that should go momentarily active when the shear
is at the bottom of its stroke. Typically this input is wired to a limit switch, cam
switch, proximity switch, or similar device. The use of the input is optional. Its
function is to force the controller’s Shear Down output to turn off before the
programmed Shear Dwell Down time elapses. This can be used to prevent a
hydraulic shear press from over-driving (bottoming-out) or to help a mechanical
press to stop at top-dead-center following each cycle. If the Shear Complete input
is not used, the controller leaves the Shear Down output active for the entire
Shear Dwell Down time during each shear cycle.
Shear Up Complete
The Shear Up Complete input is only available for Model Type XL266. The
Shear Up Complete is an input that should go active when the shear is at the top
of its stroke. Typically this input is wired to a limit switch, cam switch, proximity
switch, or similar device. The use of the input is optional. Its function is to force
the controller’s Shear Up output to turn off before the programmed Shear Dwell
Up time elapses. This can be used to prevent the material from feeding if the
shear press fails to return to its top-of-stroke position. If the Shear Up Complete
input is not used, the controller leaves the Shear Up output active for the entire
Shear Dwell Up time during each shear cycle.
Setup Lockout
The Setup Lockout input is used to prevent personnel from accessing critical data
in the XL200 Series controller. When active, machine operator is not allowed to
change most setup parameter and is restricted from performing certain functions.
The Setup Lockout is typically wired to a key-switch and it is recommended that
the key be held by a maintenance supervisor.
Manual Shear
The Manual Shear input causes the XL200 Series controller to cycle the shear
press and manually crop off any material that is under the shear blade. This
process also references the controller to the material encoder and sets the
controller’s encoder position to a known value. On some systems, the manual
shear cycle must be executed twice to reference the encoder’s position. See the
XL200 Series Operator’s Guide for more details. The Manual Shear input is not
allowed while the controller is in the run mode (unless the controller is configured
36

for a shear-only machine) but is always allowed while the controller is halted. The
Manual Shear input is typically wired to a momentary push-button.
Manual Punch
Only available on XL200 Series controllers that are configured for one or more
punch presses and/or one or more gagged presses, the Manual Punch input causes
the controller activate one its press outputs and execute a press cycle. Which press
output turns on may depend on the value of a setup parameter Tool Selected for
Manual Press. A manual press cycle is not allowed while the controller is in the
run mode. This input is typically wired to a momentary push-button.
Coil Tail-out (Sheet Detect)
The Coil Tail-out input detects the presence of material in the machine and
“qualifies” the encoder signal. Its functionality can be though of as an inverted
sheet detect. It should be wired such that the input goes in-active when the
leading edge of the material (coil) is loaded into the machine. The input should go
active when the trailing edge of the material exits the machine (when the coil tails
out). The use of this input is optional and it left unconnected the controller will
think that there is always material present. Using this input along with the
accompanying setup parameter Shear-to-Encoder Distance allows the controller
to keep track of good and scrap material during the coil loading and tail-out
processes. This input is typically wired to a photo-cell, and the sensor should be
locates just after the encoder
Press (n) Complete
The XL200 Series controller provides a Press Complete input for each press on
the machine based on the software model type and configuration dip-switch
settings. Each Press Complete input functions similar to how the Shear Complete
input works. The Press Complete input should go active momentarily when the
corresponding press is at the bottom of its stroke. When the input goes active, it
causes the controller to turn off the corresponding Press Down output before the
programmed Press Dwell Down time has elapsed. Use of this input is optional,
but it may be required on mechanical presses to cause the press to stop at top-
dead-center after each cycle. See the description for the Shear Complete input for
more details.
37

Press (n) Up Complete
Only available for Model Type XL266, the XL200 Series controller provides a
Press Up Complete input for each press on the machine based on the software
model type and configuration dip-switch settings. Each Press Up Complete input
functions similar to how the Shear Up Complete input works. The input should go
active when the press is at the top of its stroke. Typically this input is wired to a
limit switch, cam switch, proximity switch, or similar device. The use of the input
is optional. Its function is to force the controller’s Press Up output to turn off
before the programmed Press Dwell Up time elapses. This can be used to prevent
the material from feeding if any punch press fails to return to its top-of-stroke
position. If the Press Up Complete input is not used, the controller leaves the Pres
Up output active for the entire Press Dwell Up time during each press cycle.
Manual Stacker
The Manual Stacker input causes the XL200 Series controller to initiate the
stacker function. The controller’s Stacker output turns on for the specified time
and the stacker part counter is reset. This input is typically wired to a momentary
push-button.
Asynchronous Print Detect
Only available when the Print-on-Part model option is enabled and when a print
driver that supports asynchronous printing is selected, the Asynchronous Print
Detect input is used to detect the pre-cut sheet whenever a part printer is located
down-stream from the shear press. When it goes active, the XL200 Series
controller activates its Part Print Trigger output causing the part printer to print its
current message, then sends a new message to the printer to be applied to the next
part. A photo-cell is typically used for this function.
Hole Detect
Only available for model types XL200H, XL202H, XL206H, and XL212H, the
Hole Detect input is used to sense a pre-punched hole or notch in the material to
be used as a reference point for the next cut-off target. This input is typically
wired to a high-speed photo-cell with a fast response time.
38

Outputs
Fast, Slow, Reverse, and Forward
These four outputs are referred to as the motion outputs of the XL200 Series
controller. They are intended to control the motion of the machine. The table
below describes the state of each of these outputs while the controller is in various
operating modes:
Operating Fast Slow Reverse Forward Run

Mode Output Output Output Output Output
Halted Off Off/On* Off Off Off
Jog Off On Off On Off
Forward
Jog Off On On Off Off
Reverse
Run (Fast On Off Off On On
Speed)
Run (Slow Off On Off On On
Speed)
Note: The Slow output may remain On based on the value of a setup
parameter Slow Output While Halted.
Run
The Run output should be used only to latch in the controller’s run input circuit
and to activate safety devices such as horns or indicator lights to indicate when
the controller is in the Run Mode. The output turns on after the controller’s Run
input has been activated only if there is valid job data entered and there are not
error conditions that prevent the controller from entering the run mode. This
output should NOT to be used to control actual material motion.
Shear/Press Down
The Shear/Press outputs are connected directly or indirectly to solenoids that

force a shear or punch press to move in the downward direction. This output is a
timed output that remains active for the length of time specified by the
39

controller’s setup parameter Shear Dwell Down or Press Dwell Down unless
over-ridden by the corresponding Shear/Press Complete input.
Shear/Press Up
The Shear/Press Up outputs may be available depending on the XL200 Series

controller’s software model and configuration dip-switch setting. The output
should be directly connected to a solenoid that drives the shear/punch press
upward during the return stroke of its cycle. This is a timed output that remains on
for the programmed Shear/Press Dwell Up time in the controller’s setup
parameter list.
Shear/Press Die Boost
The Shear/Press Die Boost outputs may be available depending on the XL200
Series controller’s software model and configuration dip-switch setting. It is
applicable for shear/punch presses that activate on-the-fly (without the material
stopping for the operation) and that require a device that boosts (or pushes) the
die forward in the direction the material is moving. The output should be directly
or indirectly connected to a solenoid that activates the boosting device. This is a
timed output that remains on for the programmed Shear/Press Boost Dwell time
in the controller’s setup parameter list.
Item Complete
The XL200 Series controller activates the Item Complete output during the run
mode each time a programmed line item has been completed. This is a timed
output that remains active for the length of time specified by the setup parameter
Item Complete Dwell. The output can be used for a variety of functions, but is
typically connected to the input of a PLC that may be controlling some
downstream packaging equipment or other processing.
Stacker
The Stacker output is activated as part of the controller’s Indexer/Stacker function

whenever the stacker part count is reached or the counter is reset. The output is
intended to be connected to some type of automated part stacking equipment. It is
a timed output that remains active for the length of time specified by the setup
parameter Stacker Dwell.
40

Signal Ports
Analog Output #1 (Proportional to Line Velocity)
A 0-10 Volt analog output signal is generated that is directly proportional to the
current line speed as measured by the material encoder. The setup parameter
Velocity at Max Analog Voltage determines the scaling factor for this
proportional output voltage with respect to the current line velocity.
Analog Output #2 (Analog Speed Logic)
This function is only active when the Analog Speed Logic model option is
enabled. A 0-10 Volt analog output signal is generated that is intended to control
the speed of the roll former. Several additional setup parameters are provided
when this model option is enabled that are used to set this analog output to
specific voltage levels for fast, slow, and jog speeds. The voltage may also be set
up so that it is proportional to the current part length being produced (for
applications where it is desirable to run the machine at a faster speed while
making longer parts).
Comm. Port “A” (RS485 Eclipse Port)
This RS485, serial communication port is solely intended to be connected to an

office computer running the AMS Controls Eclipse software application. See the
Eclipse User’s/Installation guides for more details.
Comm. Port “B” (RS485 Auxiliary Port)
This RS485 serial communication port can be connected to a variety of auxiliary

devices including Bundle Tag and Part Printer interface cards, AMS Controls
Auxiliary Controllers, and Expansion Gag Boards. See the XL200 Series
Comm. Port “C” (RS422 High Speed Port)
This is RS422, High-Speed communication port can be connected to time-critical

devices that comply with the AMS Controls High-Speed Bus specification. Such
devices include the AMS Controls SERCOS-PC for use on multi-axis machine
applications.
41

Comm. Port “D” (RS422 High Speed Port)
This RS422 High-Speed communication port can be connected to a PLC that

complies with the industry-standard MODBUS serial communication
specification. See the XL200 Series Auxiliary Devices manual for more details.
42

Chapter 6: Setup Parameters
Once the XL200 Series controller has been customized with a specific software
model and a unique configuration dip-switch setting, it still must be tailored to the
machine’s operation using setup parameters.
Most setup parameters are determined and entered during the controller
installation process and are not usually changed during normal operation. This
chapter provides a complete listing of all possible setup parameters in the XL200
Series controller; however, not all parameters apply to each software model and
dip-switch configuration.
Setup Screen
The XL200 Series controller’s setup parameters are accessed from the Setup
screen (for details on how to navigate the controller’s screens and menus, and on
how to enter numeric and non-numeric data, see the XL200 Series Operator’s
Guide).
43

Figure 7: Setup screen
The Setup screen is divided into two sections. Menus are listed in the right-hand
section, while the parameters for the selected menu display in the right-hand
section.
This section lists and describes the most commonly used menus and their
parameters.
Machine Parameters Menu

Select the Machine Parameters menu to display the parameters that affect the
operation of the machine, including press timing, machine layout dimensions, and
run mode options.
Press Data
Includes setup parameters that are related to the operation and timing of the shear
and punch press or presses.
44

Shear Dwell Down
ID: 121
Range: 0.001 to 30.000 Seconds
Applies to: All configurations
The Shear Dwell Down parameter defines the length of time that the controller
turns on the Shear Down output during a manual or automatic shear cycle. This
may be set to the exact time necessary to move the shear die from the top of its
stroke to the bottom, or it could be set to a value longer than necessary if the
Shear Complete input is used to override the timer.
See Also: Shear Dwell Up, Shear Reaction, Expect Shear Complete, Shear
Complete Input.
Shear Dwell Up
ID: 122
Applies to: Configurations with the Shear Boost output disabled
The Shear Dwell Up parameter defines the length of time the controller turns on
the Shear Up output during a manual or automatic shear cycle. This is typically
the time necessary for the shear die to return from the bottom to the top of its
stroke. For models where the Shear Up output is unavailable the controller pauses
for this length of time during an automatic shear cycle to allow the die to return to
the top of stroke.
See Also: Shear Dwell Up, Shear Reaction, Expect Shear Complete, Shear/Press
Cycle Timing.
Shear Boost Dwell
ID: 123
Applies to: Flying-Cutoff configurations with Shear Boost enabled
The Shear Boost Dwell parameter defines the length of time the controller turns
on the Shear Boost output during an automatic shear cycle.
See Also: Shear Dwell Down, Shear/Press Cycle Timing.
45

Shear Reaction
ID: 124
Applies to: Flying-Cutoff Configurations
The Shear Reaction parameter is used to compensate for the time delay between
the instant that the controller’s Shear Down output turns on and when the shear
die makes contact with the material. The effect is that the Shear Down output
turns on early by this amount of time during an automatic shear cycle before the
programmed cutoff target is reached. Properly setting the Shear Reaction
parameter helps to avoid the common problem of the first piece is too long
following a standing (manual) cut.
See Also: Shear Dwell Down, Shear/Press Cycle Timing.
Shear Boost Reaction
ID: 125
Range: 0.000 to 1.000Seconds
The Shear Boost Reaction parameter defines the amount of time by which the
Shear Boost output turns on early with respect to the programmed cutoff target
during an automatic shear cycle. It is often used to activate the boosting device
BEFORE the Shear Down output is turned on in order to get the shear die moving
before the cut cycle is initiated.
See Also: Shear Boost Dwell, Shear Reaction, Shear/Press Cycle Timing.
Shear Boost Enable Velocity
ID: 126
Range: 0 to 1000 Feet/Min
The Shear Boost Enable Velocity parameter defines the lowest line velocity at
which the Shear Boost output becomes functional. This parameter typically
prevents the Shear Boost output from turning on during an automatic shear cycle
if the line is running too slow. If the line speed is less than this value, the Shear
Boost output will not turn on during the shear cycle. A value of 0 enables the
Shear Boost functionality at any line speed.
See Also: Shear Boost Dwell, Shear Boost Output, Shear/Press Cycle Timing.
46

Expect Shear Complete
ID: 127
Selections: Yes/No
Setting this parameter to Yes causes the controller to display an error message
(and drop out of the run mode) if the Shear Dwell Down timer expires before the
Shear Complete input goes active during a manual or automatic shear cycle.
Using this functionality with a properly mounted Shear Complete switch provides
a method to guarantee that the shear die completely cuts through the material
during each cycle.
Note: This functionality was provided in previous controller software

versions by setting the Shear Dwell Down parameter to 0.000 seconds.
See Also: Shear Dwell Down, Shear Complete Input, Shear/Press Cycle Timing.
Expect Shear Up Complete
ID: 128
Selections: Yes/No
Applies to: Model Type XL266 Only
(and drop out of the run mode) if the Shear Dwell Up timer expires before the
Shear Up Complete input goes active during a manual or automatic shear cycle.
Using this functionality with a properly mounted Shear Up Complete switch
provides a method to guarantee that the shear die has returned to its top of stroke
position before the material is fed for the next programmed target.
See Also: Shear Dwell Up, Shear Up Complete Input, Shear/Press Cycle Timing.
Press (n) Dwell Down
ID: 131,141,151,161,171,181,191,201,211,221,231
Applies to: Configurations including one or more punch presses
The XL200 Series controller provides one Press (n) Dwell Down setup parameter
for each punch press on the machine based on the model type and configuration
switch setting. The functionality is very similar to that of the Shear Dwell Down
parameter, only with respect to a punch press.
See Also: Shear Dwell Down.
47

Press (n) Dwell Up
ID: 132,142,152,162,172,182,192,202,212,222,232
Applies to: Configurations including one or more punch presses when Press
Boost outputs are disabled
The XL200 Series controller provides one Press (n) Dwell Up setup parameter for
each punch press on the machine based on the model type and configuration
switch setting. The functionality is very similar to that of the Shear Dwell Up
See Also: Shear Dwell Up.
Press (n) Boost Dwell
ID: 133,143,153,163,173,183,193,203,213,223,233
Applies to: All configurations including one or more punch presses in non-
stopping mode with Press Boost output(s) enabled
The XL200 Series controller provides one Press (n) Boost Dwell setup parameter
for each punch press on the machine based on the model type and configuration
switch setting. The functionality is very similar to that of the Shear Boost Dwell
See Also: Shear Boost Dwell.
Press (n) Reaction
ID: 134,144,154,164,174,184,194,204,214,224,234
stopping mode
The XL200 Series controller provides one Press (n) Reaction setup parameter for
each punch press on the machine based on the model type and configuration
switch setting. The functionality is very similar to that of the Shear Reaction
See Also: Shear Reaction.
48

Press (n) Boost Reaction
ID: 135,145,155,165,175,185,195,205,215,225,235
stopping mode
The XL200 Series controller provides one Press (n) Boost Reaction setup
parameter for each punch press on the machine based on the model type and
configuration switch setting. The functionality is very similar to that of the Shear
Boost Reaction parameter, only with respect to a punch press.
See Also: Shear Boost Reaction.
Press (n) Boost Enable Velocity
ID: 136,146,156,166,176,186,196,206,216,226,236
stopping mode
The XL200 Series controller provides one Press (n) Boost Enable Velocity setup
configuration switch setting. The functionality is very similar to that of the Shear
Boost Enable Velocity parameter, only with respect to a punch press.
See Also: Shear Boost Enable Velocity.
Expect Press Complete (n)
ID: 137,147,157,167,177,187,197,207,217,227,237
Selections: Yes/No
Applies to: All configurations including one or more punch presses
The XL200 Series controller provides one Expect Press Complete (n) setup
configuration switch setting. The functionality is very similar to that of the Expect
Shear Complete parameter, only with respect to a punch press.
See Also: Expect Shear Complete.
49

Expect Press Up Complete (n)
ID: 138,148,158,168,178
Selections: Yes/No
Applies to: Model Type XL266 Only when configured for one or more punch
presses
The XL200 Series controller provides one Expect Press Up Complete (n) setup
configuration switch setting. The functionality is very similar to that of the Expect
Shear Up Complete parameter, only with respect to a punch press.
See Also: Expect Shear Up Complete.
Tool Selected for Manual Punch
ID: 260
Range: 0 to 999 (Tool ID)
Applies to: All configurations for model types XL202, XL202H, XL206,
XL206H, XL212, XL212H, and XL266. Also, any configuration where the
Alternating Press (L) model option is enabled.
The Tool Selected for Manual Punch parameter determines which tool is
activated (and thus which press and gag outputs turn on) whenever the Manual
Press input is activated. This parameter allows the controller to activate any of the
tools that are defined in the Tool Data screen without requiring an individual
Manual Press input for each tool or press. This functionality can be especially
useful while troubleshooting individual tools on presses containing multiple
gagged tools.
See Also: Manual Press (Punch) input, Tool Data.
Run Mode Options
Bundle Quantity Reload Value
ID: 300
Range: 0 to 9999 (Quantity of Parts)
The Bundle Quantity Reload Value parameter forces the controller to exit the run
mode each time a pre-determined number of pieces are cut off, to allow the
machine operator time to package a bundle.
50

For example, if a production run requires a large number of parts to be run, and
the operator wants the machine to stop after every 50 pieces, set this parameter to
50. After the controller cuts 50 pieces, the machine will stop and the Bundle
Quantity Counter gets reloaded to 50. Entering a value of 0 (zero) disables the
Bundle Quantity Counter feature.
Note: The controller still exits the run mode at other appropriate times,
depending on the Halt Mode setup parameter.
See Also: Bundle Quantity Count, Halt Mode
Bundle Quantity Count
ID: 301
Range: 0 to 9999 (Quantity of Parts)
Used in conjunction with the Bundle Quantity Reload parameter, the Bundle
Quantity Count parameter creates additional bundle stops. The Bundle Quantity
Count displays the running total (a decrementing counter) of parts remaining
before the next bundle stop. As soon as this value decrements to zero, the
machine halts and this counter is re-loaded with the Bundle Quantity Reload
Value.
See Also: Bundle Quantity Reload Value, Halt Mode
Item Complete
ID: 302
Applies to: All configurations except model type XL255
The Item Complete parameter defines the length of time that the Item complete
output turns on at the completion of each Item while the controller is in the run
mode. This output is often used to machinery running (an exit conveyor, for
example) for a given length of time after the last part of an item has been
produced the controller has exited the run mode.
See Also: Item Complete output.
Delay After Shear
ID: 303
51

The Delay After Shear parameter defines the length of time that the controller
waits after each automatic shear cycle before turning on the motion outputs to
start feeding the next part. This is typically used to create separation between
parts and allows time for an exit conveyor to move the last cut part out of the way
before a new part begins to feed.
Note: The controller remains in the run mode during this delay period and the
Run output remains active.
Minimum Slow Distance
ID: 304
Range: 0.000 to 100.000 Inches
Applies to: Any configuration configured for two-speed operation
The Minimum Slow Distance parameter defines the minimum distance prior to
each punch and cutoff target that the controller commands the machine to shift
from fast to slow speed. The speed shift point may occur even earlier than this
distance depending on the Deceleration Mode setup parameter.
For best accuracy, the Minimum Slow Distance should be set large enough so that
the machine is able to de-accelerate to a consistent, stable slow speed before the
current punch or cutoff target is reached.
See Also: Deceleration Mode, Deceleration Factor
Scrap Part Length
ID: 305
Applies to: Any configuration that supports punching
The Scrap Part Length parameter defines the length of shear-only scrap parts that
will be made any time the controller enters the run mode and is unable to produce
the currently programmed part. This scenario can occur after a new coil is loaded
onto the machine, or after any time the controller’s target queue is cleared. If the
currently programmed part requires a punch operation at a location which has
already passed the punch press, the controller will automatically insert scrap parts
of this length until the first good part can be made.
Entering a Scrap Part Length of zero instructs the controller to produce parts at
the current programmed length, upon entering the run mode, even if some or all
of the punch operations can not be included in the part(s).
See Also: Clear Queue After, Tool Data, Part Programming
52

Halt Mode
ID: 306
Selections: Item Halt / Bundle Halt / Order Halt / Never Halt
The Halt Mode parameter determines when the controller will execute an
automatic line halt (exits the run mode) during production. The Halt Mode has
four available options:
• Item Halt
The controller exits the run mode after the completion of every line Item.
• Bundle Halt
The controller exits the run mode after the completion of a line Item only it
the next item’s Bundle Number is different from the previous line item or if it
is the last Item of the current Order.
• Order Halt
The controller exits the run mode after the completion of a line Item only
when it is the last Item of the current Order.
• Never Halt
The controller exits the run mode after the completion of a line Item only
when it is the last Item of the current Order, and the next Order’s Material or
Product Code definition is different from the current Order.
See Also: Bundle Quantity Reload Value, Bundle Quantity Count, Order/Item
Programming.
Halt No More Items to Run
ID: 307
Selections: Yes / No
Applies to: Any configuration that supports punching
• When set to Yes, this parameter causes controller to exit the run mode
whenever it detects that there are no more punch or shear targets in its queue
for the current Material or Product Code. A message is displayed to the
machine operator, giving him the opportunity to program more parts at this
time and possibly avoid producing extra scrap.
• When set to No, the controller runs until the punch/shear target queue is empty
without displaying the operator message.
53

Stopping Reaction Mode
ID: 309
Selections: Automatic / Manual / Off
Applies to: Any configuration configured for feed-to-stop operation
This parameter determines how the controller uses the Stopping Reaction Time to
control the machine each time it stops for a shear or punch operation. The
following Stopping Reaction Modes are available:
• Automatic
The controller turns off its motion outputs prior to the actual shear or punch
target, assuming the machine’s inertia will allow the target to coast into the
correct position. If the material stops such that the target is within the
programmed Tolerance range, the shear or punch press is activated and a new
Stopping Reaction Time is iteratively calculated to be used for the next target.
The iteration is based on how close the machine was able to stop in reference
to the programmed target location.
• Manual
The controller turns off its motion outputs prior to the actual shear or punch
target the same as in the Automatic mode; however, it does NOT calculate a
new Stopping Reaction Time. The value entered for the Stopping Reaction
Time remains constant while in Manual mode.
• Off
This mode is provided so that the Stopping Reaction Time calculation and
compensation can be disabled altogether. The controller will turn off the
motion outputs as soon as the programmed shear or punch target is reached.
Typically the machine’s inertia causes the material to coast beyond the
programmed target location while in this mode. If the amount of this coast
distance is consistent, the machine can still produce relatively accurate parts,
however this often leads to a first part is long scenario following a standing
cut.
Note: The controller’s tolerance test is not performed while the Stopping
Reaction Mode is set to Off.’
See Also: Stopping Reaction Time, Tolerance
54

Stopping Reaction Time
ID: 310
This parameter represents the amount of time in advance of the each shear or
punch target that the controller commands the machine to stop (unless the
Stopping Reaction Mode is set to Off’). It is a rough indication of how long it
takes the machine to stop once the controller’s motions outputs have been turned
off.
See Also: Stopping Reaction Mode, Tolerance
Deceleration Mode
ID: 311
Selections: Automatic / Manual / Off
This parameter determines how the controller uses the Deceleration Factor to
control the machine each time it shifts from fast speed to slow speed. The
following Deceleration Modes are available:
• Automatic
The controller commands the machine to shift from fast to slow speed prior to
the programmed Minimum Slow Distance before each shear or punch target.
The controller detects whether or not a stable slow speed was reached prior to
the Minimum Slow Distance target and iteratively calculates a new
Deceleration Factor to be used for the operation.
If properly calibrated on a machine that demonstrates consistent behavior, the
Automatic Deceleration Mode allows the controller to choose the optimum
point at which to initiate the speed shift, allowing the machine to reach a
consistently stable slow speed prior to each target, and maximizing the
amount of time the machine is able to run in fast speed.
• Manual
The controller commands the machine to shift from fast to slow speed prior to
the programmed Minimum Slow Distance the same as in the Automatic mode;
however, it does NOT calculate a new Deceleration Factor. The value entered
for the Deceleration Factor remains constant while in Manual mode.
• Off
This mode is provided so that the Deceleration Factor calculation and
compensation can be disabled altogether. The controller will command the
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machine to shift from fast to slow speed at the programmed Minimum Slow
Distance before the programmed shear or punch target.
See Also: Deceleration Factor
Deceleration Factor
ID: 312
Range: 4.0 to 1000.0 Inches/Sec/Sec
This parameter represents the estimated deceleration rate of the machine

calculated (depending on the Deceleration Mode) each time the controller
commands the machine to shift from fast to slow speed. This value is used to
adjust the point at which the controller commands the machine to shift from fast
to slow speeds prior to each shear or punch target (unless the Deceleration Mode
is set to Off’).
See Also: Deceleration Mode
Tolerance
ID: 313
This parameter defines the maximum amount of position error the controller
allows before activating a shear or punch press for a given target while in the run
mode. Each time the machine stops for a programmed target location (and the
Stopping Reaction Mode is not set to Off’) the XL200 Series controller performs
a tolerance test by comparing the current encoder position to the programmed
target location.
If the Current Encoder Position is:

• Greater than (Programmed Target + Tolerance)
• or
• Less than (Programmed Target – Tolerance)
then the shear or punch press is not activated, and the controller displays an
appropriate error message and exits the run mode.
See Also: Stopping Reaction Mode
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Alternating Press Mode
ID: 315
Selections: Alternating / Single
Applies to: Only when the Alternating Press (L) model option is enabled
This parameter can be used to enable or disable the Alternating Press

functionality. The following Alternating Press Modes are available:
• Alternating
The Alternating Press functionality is enabled. This feature allows the user to
program Punch Patterns with operations for only one of the two available
punch presses. When an item with a punch pattern is run, the controller
automatically alternates between activating the two punch presses. This
feature can be used to provide increased production rates on machines that are
limited by the cycle time of a single punch press, if duplicate punch tooling is
available.
• Single
The Alternating Press functionality is disabled, causing the controller to
activate the punch presses exactly as they programmed in the Punch Pattern.
See Also: Programming Patterns
Stitch Gag
ID: 316
Range: 0 to nn (where nn is the maximum number of gag outputs available
for the current model type and configuration switch setting.
Applies to: All configurations that support gagged punch tooling, model types
XL202, XL202H, XL206, XL206H, XL212, and XL212H
This parameter determines which gag output the controller turns on whenever it
executes a stitch cut operation. This functionality is intended for machines that
are capable of performing a stitch cut where the shear press contains special
tooling that prevents it from cutting completely through the material. Typically a
gagged tool is engaged during this operation that allows the shear to perform the
stitch cut.
Note: Stitch Cut capability is typically found on pre-cut machines and is used
to prevent the control system from shearing a part that is too short to pass
through the roll former tooling.
See Also: Max Auto Stitch Length
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Max Auto Stitch Length
ID: 317
Applies to: All configurations that support gagged punch tooling, model types
XL202, XL202H, XL206, XL206H, XL212, and XL212H
This parameter defines the shortest length of material the controller will cut off
without engaging the Stitch Gag output. Any time a length of material is cut off
(during an automatic shear cycle) that is shorter than this parameter, the controller
will automatically activate the Stitch Gag output during the shear cycle.
Note: The Max Auto Stitch Length parameter doesn’t appear in the list unless
a non-zero value is entered for the Stitch Gag parameter.
See Also: Stitch Gag
Slow Output While Halted
ID: 318
Selections: Off / On
This parameter determines whether the Slow output is turned On or Off while the
controller is halted (i.e. not in the run, jog forward, or jog reverse modes).
Note: Some hydraulic-driven machines may require the controller’s Slow

output to be left on while halted depending on the configuration of the
hydraulic valves.
Stacker Dwell
ID: 319
Applies to: All configurations, machines with automatic part stacking equipment
This parameter determines the length of time the XL200 Series controller turns on
its Stacker output during an automatic or manual stacker operation.
Entering a Stacker Dwell of zero disables the stacker functionality.
See Also: Stacker Delay, Parts Per Stack, Expect Stacker Compete
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Stacker Delay
ID: 319
This parameter defines the length of time the XL200 Series controller waits
before activating the Stacker output whenever it is time to perform an automatic
stacker operation.
See Also: Stacker Dwell, Parts Per Stack, Expect Stacker Compete
Parts Per Stack
ID: 319
Range: 0 to 999
This parameter defines the number of parts the controller must produce during the
run mode before performing an automatic stacker operation. The XL200 Series
controller keeps a running count of the number of parts it makes during the run
mode. As soon as this count is equal to the Parts Per Stack parameter, it initiates
an automatic stacker operation (turns on the Stacker output for the programmed
Stacker Dwell time after waiting for the programmed Stacker Delay time).
• Any time a stacker operation occurs, the internal part counter gets reset to
zero. Several other events cause a stacker operation to occur, including:
• The Manual Stacker input is activated.
• Any time the controller transitions from one Item to another Item during the
run mode.
• Any time the machine operator sets a new Item to Next status.
• Any time the controller’s queue is cleared following a manual shear operation.
See Also: Stacker Dwell, Stacker Delay, Expect Stacker Compete
Expect Stacker Complete
ID: 319
Applies to: Model type XL266 only
(and drop out of the run mode) if the Stacker Complete input does not go active
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after an appropriate amount of time elapses once the stacker operation has been
initiated. It also prevents the controller from feeding the next part until the
Stacker Complete input is detected. The controller will not be allowed to enter the
run mode if the Stacker Complete input is not active.
Setting this parameter to No disables the functionality of the Stacker Complete

input and removes the restrictions mentioned above.
See Also: Stacker Dwell, Stacker Delay, Parts Per Stack
Crash Detect Velocity Change
ID: 321
Range: 0 to 1000 Feet/Minute
Applies to: All flying-cutoff configurations
Used in conjunction with the Crash Detect Time parameter, these values
determine the maximum rate of deceleration the controller will allow before
dropping out of the run mode and displaying an error message. This feature
intended to help identify material jam-up conditions that occur on the machine
prior to the location of the material encoder. A sudden drop in line velocity
detected by the XL200 Series controller will be regarded as a crash condition and
all motion outputs will be turned off to help prevent equipment damage and injury
to personnel.
Note: Entering a value of zero disables the Crash Detect feature.

See Also: Crash Detect Time
Crash Detect Time
ID: 321
Applies to: All flying-cutoff configurations
Used in conjunction with the Crash Detect Velocity Change parameter, these
values determine the maximum rate of deceleration the controller will allow
before dropping out of the run mode and displaying an error message.
Note: Entering a value of zero disables the Crash Detect feature.

See Also: Crash Detect Velocity Change
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Test Part Length
ID: 330
This parameter defines the length of the test part the XL200 Series controller
produces any time the Test Part function key is pressed while the controller is in
the run mode.
Use Coil Inventory
ID: 333
Setting this parameter to No removes all references to the XL200 Series

controller’s Coil Inventory management and tracking features. The controller will
not prompt the operator to enter any coil inventory numbers, and the Coil
Inventory menu will no longer appear on the Production Data screen.
See Also: Allow Coil Override
Allow Coil Override
ID: 334
Selections: Always / Only With Key
Applies to: All configurations, only when Use Coil Inventory is set to Yes’
This parameter whether the controller will allow the machine operator run an
Order whose material definition doesn’t match the material defined for the
currently loaded coil. When set to Always the operator always has the authority to
override this condition. When set to Only with Key, the operator does not have
the authority to override this condition unless the Setup Lockout input is
unlocked.
See Also: Use Coil Inventory
Bump Tolerance
ID: 338
Applies to: Model Type XL266 (stopping operations) only
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If the XL200 Series controller stops for a shear or punch target and is not within
the programmed Tolerance, but is within the programmed Bump Tolerance, the
controller will attempt to bump the material either forward or backward to try and
achieve tolerance. A bump move is attempted by turning on the appropriate
motion output(s) for the programmed Bump Time.
Enter a value of zero for this parameter disables the Bump into Tolerance feature.
See Also: Bump Time, Tolerance
Bump Time
ID: 339
Applies to: Model Type XL266 only
This parameter defines the length of time the controller turns on its motion
outputs while attempting to bump the material within the programmed tolerance.
Enter a value of zero for this parameter disables the Bump into Tolerance feature.
See Also: Bump Tolerance, Tolerance
Machine Layout
Coil End Point
ID: 350
This parameter defines the distance from the back edge of the shear to a point on
the machine where the material is typically cut free when there are no more orders
to run for the current coil. When this parameter is set correctly, the XL200 Series
controller will exit the run mode when there is just enough material remaining in
the machine to complete the current order any time it detects an upcoming
material or product code change. A message is displayed to the operator
informing him that it is time to cut the remainder of the coil free.
This feature is intended to minimize unnecessary scrap on post-cut machines by

preventing extra material from passing through the roll former. Entering a value
of zero disables the Coil End Point feature.
See Also: Coil End Offset
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Coil End Offset
ID: 351
This parameter provides a means to delay the Coil End Point feature from
occurring if it is too close to a current shear target. The Coil End Point feature
will be delayed if it occurs when the next shear target is within the Coil End
Offset distance from reaching the shear press.
For example, suppose the Coil End Point is set to 120 inches, and the Coil End
Offset is set to 12.000 inches. If the controller encounters the Coil End Point
condition, but the next shear target is within 12 inches from reaching the cutoff
press, the line will continue running so that the shear operation can take place
before the Coil End Point halt occurs.
See Also: Coil End Point
Encoder Direction
ID: 352
Selections: CW / CCW
This parameter determines the counting direction for the material encoder. Set to
CW if the material causes the encoder wheel to turn clockwise when moving in
the forward direction. Set to CCW if the material causes the encoder wheel to turn
counter-clockwise when moving in the forward direction.
Shear Kerf
ID: 353
This parameter should be set to a value that equals the amount of material that
gets removed by the shear die when it cuts through the material. The XL200
Series controller will automatically compensate for this material by producing
each programmed part length extra long by the Shear Kerf distance.
For shear dies that have a cutting action similar to a pair of scissors (no material is
removed) enter a value of zero for the Shear Kerf.
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Minimum Part Length
ID: 354
This parameter defines the shortest part length that the XL200 Series controller
allows the machine operator to enter while in the Program screen. It should be set
to the shortest part length that the machine is able to run.
Shear to Encoder Distance
ID: 355
Range: 0.0000 to 10000.0000 Inches
This parameter detects leading edge of a coil, and accurately records scap
material when the coil tails out.
Note: Always set this value to the measured distance between the tail-out
sensor and the back edge of the shear die, depending on the orientation of the
encoder and the sensor. For the best accuracy, the material encoder and the
coil tail-out sensor should be positioned so that they are equidistant from the
shear die.
See Also: Coil Tail-out Input, Enable Shear Encoder Distance 2, Shear to Encoder
Distance 2, Production Tracking - Scrap Material
Machine Material Y Reference
ID: 370
Selections: Center / +Edge / -Edge
Applies to: Only when the Multi-Axis (X) model option is enabled
This parameter specifies whether the material is center-guided or edge-guided. It

edge-guided, it specifies whether it is guided on the positive edge or the negative
edge of the machine.
See Also: Multi-Axis applications
Enable Multi-Angle Shear
ID: 371
Selections: Center / +Edge / -Edge
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Applies to: Only when the Multi-Axis (X) model option is enabled AND the
Machine Material Y Reference parameter is not set to Center’
Setting this parameter to Yes allows the multi-axis controller to perform leading-
edge and trailing-edge shear operations using varying angles. Very specialized
machinery is required to correctly utilize this feature.
See Also: Multi-Axis applications
Clear Queue After
ID: 372
Selections: Double Shear / Single Shear
Applies to: Any configuration that supports punching or gagged tooling
This parameter determines whether the XL200 Series controller clears all of the
punch and shear targets from its queue following one manual shear (Single Shear)
operation of two manual shear (Double Shear) operations.
Enable Shear Encoder Distance 2
ID: 373
Setting this parameter to Yes allows additional setup parameters to appear in the
list, related to the use of a second material encoder and tail-out sensor.
See Also: Shear to Encoder Distance 2, Coil Trim Cut Distance
Shear to Encoder Distance 2
ID: 374
Range: 0.0000 to 10000.0000 Inches
Applies to: All configurations, whenever the setup parameter Enable Shear
Encoder Distance 2 is set to Yes’
This parameter should be set to the measured distance between the second
material encoder and the back edge of the shear die. The XL200 Series controller
uses this parameter when a new coil is loaded, and uses the other Shear to
Encoder Distance value whenever the coil tails out.
Using this parameter requires that a second tail-out sensor (and a second material
encoder) be located on the machine upstream from the first sensor and encoder.
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The two sensors must be wired such that when either sensor detects the presence
of material, the controller’s tail-out input goes inactive.
See Also: Shear to Encoder Distance, Coil Tail-out Input, Enable Shear Encoder
Distance 2, Coil Trim Cut Distance, Production Tracking - Scrap Material
Coil Trim Cut Distance
ID: 375
Applies to: All configurations, whenever the setup parameter Enable Shear
Encoder Distance 2 is set to Yes’
This parameter defines the length of the leading edge trim cut that the XL200
Series controller when it enters the run mode for the first time after a new coil is
loaded. The automatic trim cut references the leading edge of the material and
allows the controller to produce an accurate first part without requiring the
machine operator to thread the coil all the way through the machine and perform a
manual standing crop.
See Also: Shear to Encoder Distance, Coil Tail-out Input, Enable Shear Encoder
Distance 2
Front Shear Tool
ID: 376
Range: 0 to 999 (Tool ID)
Applies to: Model type XL200 when configured when with a feed-to-stop punch.
Model type XL266 when configured for at least one punch press.
This parameter determines which tool is designated as the Front (Entry) Shear.
Machines equipped with an entry shear are capable of accurately cutting off the
coil before it enters the roll former in order to prevent scrap material near the end
of an order. Correctly entering the Front Shear Tool ID along with the correct
Tool Data offset for this shear allows the controller to automatically stop the
machine when the exactly enough material remaining to complete the current
order (Similar to how the Coil End Point feature works, only more accurate). The
controller automatically activates the Front Shear to cut off the remainder of the
coil whenever this condition occurs, so the trailing edge of the last part before a
material change is cut accurately
See Also: Coil End Point, Front Shear Advance, Tool Data.
66

Front Shear Advance
ID: 377
Applies to: Model type XL266 when configured for at least one punch press.
Setting this parameter to Yes causes the controller to turn on its motions outputs
and begin feeding the material between the out stroke and the return stroke of the
Front Shear cycle.
See Also: Front Shear Tool
Hole Detect Options
Hole Mode Select
ID: 400
Applies to: Model types XL200H, XL202H, XL206H, & XL212H
This parameter can be used to enable or disable all the hole-detect features of the
XL200 Series controller.
When set to Count Hole mode the controller determines the programmed part
length by defining a number of holes to be counted by the hole detector.
When set to Standard mode, the controller operates as if the Hole Detect model
were not specified. The part lengths produced are determined by the length
programmed in each Item.
The Hole Mode Select parameter may not be changed while the controller is in
the run mode.
See Also: Hole-Detect Operating Mode, Programming Items (Hole-Detect Mode)
No Hole Stop Distance
ID: 401
Range: 0.0000 to 3499.9999 Inches
Applies to: Model types XL200H, XL202H, XL206H, & XL212H
This parameter can be used to enable a safety feature in the XL200 Series
controller while operating in Hole Detect mode. If a length of material greater
than this distance passes by the material encoder without the controller sensing
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any transitions of its Hole Detect input, the controller will exit the run mode and
display an error message to the operator indicating the hole detector has failed.
A value should be entered that is greater than the largest expected distance
between consecutive holes on the part. Entering a value of zero disables this
feature.
See Also: Hole-Detect Operating Mode
Hole Detect Logic
ID: 402
Selections: Normal / Inverted
Applies to: Model types XL200H, XL202H, XL206H, XL212H, & XL266
This parameter determines the logic (active-high or active-low) required on the

controller’s Hole Detect input in order to register a hole. Use this in cooperation
with the sensor’s light-on / dark-on setting to provide the desired operation.
See Also: Hole-Detect Input
Minimum Hole Spacing
ID: 404
Range: 1.0000 to 3499.9999 Inches
This parameter must be used to prevent the XL200 Series controller from
detecting the same hole twice. It should be set to a value that is slightly larger
than the expected hole diameter, but smaller than the minimum expected distance
between consecutive holes. Once the controller senses a hole, the material
encoder must move at least this distance before the controller will register another
hole.
Shear to Detector Distance
ID: 404
Range: 1.0000 to 3499.9999 Inches
This parameter should be set to the measured distance from the hole-detect sensor
to the back edge of the shear blade while the shear die is at its home position. This
parameter must be set large enough to allow the controller enough time to queue
68

up a target whenever the hole is detected; however, keeping this distance as short
as possible typically provides the best cutting position accuracy.
Advanced Setup
Line Resolution
ID: 450
Range: 0.0400000 to 0.0000400 Inches per Count
This parameter specifies the resolution for the XL200 Series controller’s material
encoder (a.k.a. Line Encoder). The encoder’s resolution is defined as the distance
of material movement for every encoder count registered by the controller.
On a typical configuration where a measuring wheel is directly coupled to the

shaft of the material encoder, and the wheel rides directly on the material surface,
the resolution can be calculated using the following formula:
Wheel Circumference
Resolution =
# of Encoder Counts in one Revolution
Most commercially available encoders, including those supplied by AMS

ControlsControls, provide two channels of square wave pulses and are specified
in pulses-per-revolution (PPR). The XL200 Series controller registers an encoder
count on the rising and falling edge of each pulse on each channel. Thus the
number of encoder counts per revolution is equal to the number of pulses-per-
revolution times four (PPR x 4).
69

The following table lists the correct Line Resolution when using an AMS
Controls encoder with a 12-inch circumference measuring wheel in the typical
configuration described above:
AMS Controls Typical Line Resolution
Encoder Model
Number
256 .001171875
500 .00600000
1000 .00300000
2000 .00150000
It is not necessary to precisely measure the wheel circumference. Nominal values

can be used with accurate results achieved during the Trim Correction process.
See Also: Correction Factor, Trim Correction
Velocity at Max Analog Voltage
ID: 500
Applies to: All configurations except model type XL266
This parameter can be used to enable the Analog Voltage Proportional to Line
Velocity feature of the XL200 Series controller. Whenever a non-zero value is
entered for this parameter, the controller provides an analog output voltage (on
Analog Port #1) that is proportional to the current line velocity as measured by
the material encoder.
This parameter specifies the minimum line velocity for which a 10 Volt output
signal will be provided. The voltage output will be 0 Volts whenever the
measured line velocity is 0 Feet/Minute and it will be linearly proportional for
any velocity within this range.
Note: This feature is active for any and all movement reported by the material
encoder whether the controller is in the run mode or not. Entering a value of
zero disables this feature.
Auxiliary Shear Compensation
ID: 501
Range: 0.0000 to 1000.0000 Inches
Applies to: Any configuration where the Auxiliary Controller (S) model option is
enabled
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This parameter is used to compensate for a long first part produced following a
manual shear operation when the shear press is being controller by an auxiliary
controller. The XL200 Series controller will adjust the length of the first part is
produces (after any time its queue has been cleared) by this amount.
This parameter will be required on any machine configuration if the Shear output
of the XL200 Series controller is wired directly into the Hole Detect input of the
auxiliary controller. The value that should be used for this parameter can be
calculated by taking the sum of two of the setup parameters found in the auxiliary
controller: Shear-to-Detector distance plus Manual Shear Die Distance.
See Also: Auxiliary Controller Operation
Die Boost Compensation
ID: 502
Applies to: Any flying-cut configuration where the Shear Die Boost functionality
is enabled
This parameter is used to compensate for the condition where the first part
produced following a manual shear is the wrong length due to the fact that the Die
Boost output doesn’t activate during a manual shear cycle. Enter a value equal to
the average distance that the Die Boost output causes the die to travel before it
makes contact with the material during an automatic shear cycle.
See Also: Shear Die Boost Output
Filter Constant
ID: 503
Range: 1.0 to 200.0 Hertz
This parameter is used by the XL200 Series controller’s velocity calculation. It

can be adjusted to help improve the controller’s responsiveness to changes in line
velocity. Lower values should be used on machines with relatively stable
velocities while higher values can be used on machines with fluctuating
velocities.
Note: The default value of 32.0 Hz has been experimentally determined as the
optimum Filter Constant for most applications. Very rarely should it be
necessary to change this value.
71

Minimum Speed Voltage
ID: 504
Range: 0.0 to 10.0 Volts
Applies to: Only when the Analog Speed Logic (AA) model option is enabled
Maximum Speed Voltage
ID: 505
Length at Maximum Speed
ID: 506
Range: 0.0000 to 3499.9999 Inches
Jog Speed Voltage
ID: 507
These four parameters are used to control the XL200 Series controller’s Analog
Speed Logic feature. They represent the analog voltage output produced (on
Analog Port # 2) by the controller during the run mode (Fast and Slow speeds)
and during the jog mode.
Jog Speed Voltage defines the voltage produces while the controller is in the jog
mode (forward or reverse).
Minimum Speed Voltage defines the voltage produced while the controller is in
the run mode, running at slow speed.
Maximum Speed Voltage defines the maximum voltage produced while the
controller is in the run mode, running at fast speed. The voltage produced during
this mode may be scaled to value between Max and Min depending on the Length
at Maximum Speed parameter.
Length at Maximum Speed is used to scale the analog voltage produced during
the run mode (at fast speed) in proportion to the current part length being run.
This provides the functionality of automatically being able to run the machine
faster for long parts and slower for short parts. This parameter defines the shortest
part length at which the maximum voltage (10 Volts) will be applied during the
72

run mode, at fast speed. The voltage applied during this mode for parts shorter
than this length will be linearly scaled between Min and Max.
Trim Correction
Last Programmed Length
ID: 775
This parameter is used in the automatic Correction Factor calculation described

below.
See Also: Last Measured Length, Correction Factor
Last Measured Length
ID: 776
This parameter is used in the automatic Correction Factor calculation described

below.
See Also: Last Programmed Length, Correction Factor
Correction Factor
ID: 777
Range: 95.000 to 105.000 %
This parameter is used by the XL200 Series controller to automatically scale all
programmed part lengths (and punch locations) to be made longer or shorter. This
is typically used to compensate for inaccuracies in determining the precise
circumference of the material encoder’s measuring wheel. The formula for
calculating a new Correction Factor is described below:
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⎛ Programmed Length ⎞
New CF = ⎜ ⎟ × Old CF
⎝ Actual Measured Length ⎠
where CF = Correction Factor
For best results, AMS Controls recommends you take a sample of several
measured parts and use the average length as the actual measured length.
The XL200 Series controller will automatically perform this calculation whenever
values are entered for the Last Programmed Length and Last Measured Length
parameters.
The Correction Factor parameter and Trim Correction feature should only be used
when measured parts are coming out consistently long or consistently short.
Varying part lengths typically indicates some other machine problem (See the
XL200 Series Troubleshooting Guide for more information).
See Also: Last Programmed Length, Last Measured Length
Controller Settings
Select the Controller Settings menu populates the parameter list with parameters
that affect the general operation and appearance of the XL200 Series controller
such as time and date formatting, number formatting preferences, and language
settings. This list is subdivided into the following categories.
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Clock / Calendar
Figure 8: Clock/Calendar Setup Screen
Time Format
ID: 600
Selections: AM-PM / 24-Hour
Applies to: All Configurations
This parameter determines the format for the XL200 Controller’s built-in real-
time clock. AM-PM allows for a 12-hour style, while 24-Hour allows for
military-style 24-hour readout. This format will be used when displaying the real-
time clock (in the top right corner of the screen) and for any printed data that
includes a time/date stamp.
Date Format
ID: 601
Selections: MM-DD-YY / DD-MM-YY / YY-MM-DD
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This parameter determines the format for the XL200 Controller’s built-in real-
time calendar. It allows the date to be displayed in the format that the machine
operator is most familiar with.
MM = Month, DD = Day, YY = Year.
This format will be used when displaying the real-time calendar (in the top-right
corner of the screen) and for any printed data that includes a time/date stamp.
Date Separator
ID: 602
Selections: / - or .
This parameter determines the character used to separate the months, days, and
years when the XL200 Series controller displays its real-time calendar.
See Also: Date Format
Set Hours, Set Minutes, Set Seconds, Set AM or PM, Set Days, Set
Months, Set Year
IDs: 603-609
Range: Typical Clock/Calendar
These parameters allow the user to configure the XL200 Series controller’s built-
in real-time clock and calendar if necessary.
Note: When the controller is networked to a PC running the AMS Controls

Eclipse Production Management software, the real-time clock/calendar is
automatically set to match the one on the Eclipse PC.
Network Settings
The Network Settings menu contains parameters that pertain to the AMS Controls
Eclipse Production Management software. Up to 30 XL200 Series controllers can
be connected on a single network for communicating with a computer running the
Eclipse software. See the Eclipse Technical Reference and User’s Guides for
more information.
Note: Most of the parameters described below do not appear in the list until a
valid Network Unit ID has been entered.
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Network Unit ID
ID: 650
Range: 0 to 30
This parameter specifies a unique identifier on the Eclipse network. Each XL200
Series controller on the network must have a unique Network Unit ID, and must
have a matching Machine ID assigned for it at the Eclipse PC.
Entering a Network Unit ID of zero disables all Eclipse-related features.
Network Baud Rate
ID: 651
Selections: 460800, 230400, 115200, 76800, 57600, 38400, 28800, 19200, 9600,
4800 Bits/Second
This parameter sets the data communications rate for the Eclipse network. The
Network Baud Rate for each XL200 Series controller on the network must match
the corresponding baud rate set on the Eclipse PC.
Note: The network baud rate may be limited by the maximum rate supported
by the PC and/or by any communication interface adapters installed on the
network. Consult the Eclipse Technical Reference Guide for more
information.
Halt Delay Minimum
ID: 652
Range: 0 to 99 minutes
This parameter is used in cooperation with the Eclipse functionality of tracking

machine down-time. This value specifies the minimum amount of time after
which the XL200 Series controller has been halted (i.e. not in the run mode) that
it will prompt the machine operator to enter a delay reason the next time he enters
the run mode. In other words, once the controller exits the run mode, if it is halted
for a time longer than is specified by this parameter, the machine operator must
provide a reason why the machine was stopped for so long.
Entering a value of 99 minutes disables this feature.
See Also: Delay Reasons, Eclipse Downtime Tracking
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Auto-Request Order Footage
ID: 653
Range: 0 to 9999 feet
This parameter is used in cooperation with the Eclipse functionality of automatic

order scheduling. This value provides a threshold such that whenever the total
remaining footage of all orders currently programmed in the XL200 Series
controller drops below this number, the controller sends a request to the Eclipse
PC or more orders to be sent down.
See Also: Eclipse Automatic Order Scheduling
Use Scrap Codes
ID: 654
This parameter is used in cooperation with the Eclipse functionality of scrap

material reporting. Setting this parameter to Yes causes the XL200 Series
controller to prompt the machine operator to enter a scrap code for any event that
the controller determines to be creating scrap material. Such events include:
Performing the Increment Quantity function and using the Remake function.
See Also: Eclipse Material Usage Reporting
Manual Shear Scrap Length
ID: 655
Range: 0 to 1000 inches
This parameter is used in cooperation with the Eclipse functionality of scrap

material reporting and the XL200 Series controller setup parameter Use Scrap
Codes. This value specifies the minimum amount of material that must be cut off
by a manual shear operation which causes the controller to prompt the machine
operator to enter a scrap code. All material removed by a manual shear operation
is recorded by the controller as scrap, but by setting this parameter correctly the
machine operator will not be prompted to enter scrap reasons for insignificant
lengths of material.
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Any material removed by manual shear operation which is less than this length,
will be automatically assigned the scrap code of zero if Use Scrap Codes is
enabled.
See Also: Eclipse Material Usage Reporting
Enforce Eclipse Coil Validation
ID: 656
This parameter is used in cooperation with the Eclipse coil inventory management
feature. Setting this parameter to Yes prevents the XL200 Series controller from
entering the run mode, after a new coil is loaded, until the coil inventory number
has been validated by the Eclipse PC. During the coil loading process, the
controller sends the coil number to the Eclipse PC where it is verified to exist in
the Coil Inventory database. If the coil number was invalid, the controller will not
be allowed to enter the run mode until the correct inventory number is entered.
Note: For cases where the Eclipse network communications is temporarily

unavailable, the coil validation process can be overridden by unlocking the
controller’s Setup Lockout input.
See Also: Eclipse Coil Inventory Database
PLC Communication
The PLC Communication menu appears only when the PLC Integration (I) model
option is enabled. This menu contains parameters that pertain to the data transfer
between the XL200 Series controller and a PLC that conforms to the MODBUS
communications specification.
Note: Most of the parameters described below do not appear in the list until a
valid PLC Unit ID has been entered.
PLC Unit ID
ID: 675
Range: 0 to 247
Applies to: Only when the PLC Integration (I) model option is enabled
This parameter specifies a unique identifier for the MODBUS capable PLC that
the XL200 Series controller communicates with.
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Entering a PLC Unit ID of zero disables all communication between the

controller and the PLC.
PLC Baud Rate
ID: 676
Selections: 460800, 230400, 115200, 76800, 57600, 38400, 28800, 19200, 9600,
4800 Bits/Second
This parameter sets the data communications rate for communicating with the
MODBUS-capable PLC. The PLC Baud Rate must match the corresponding baud
rate set on the PLC.
Note: The network baud rate may be limited by the maximum rate supported
by the PLC and/or by any communication interface adapters installed on the
network.
PLC Parity
ID: 677
Selections: None / Even / Odd
This parameter sets the data communications parity setting for communicating
with the MODBUS-capable PLC. The PLC Parity must match the corresponding
parity setting on the PLC.
PLC Stop Bits
ID: 679
Selections: 1 or 2
This parameter sets the number of stop bits used while communicating with the
MODBUS -capable PLC. The PLC Stop Bits must match the corresponding stop
bits setting on the PLC.
Configuration Register Address
ID: 678
Range: 0 to 999999999
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This parameter specifies the starting address for the PLC holding register where
the configuration data is stored. The XL200 Series controller must be able to read
valid configuration data at this address before any other communication can
occur.
See Also: Using the PLC Integration (MODBUS) Option
Operator Preferences
Language Select
ID: 700
Selections: English / Spanish / French / Italian / Russian
This parameter determines the language for all text displayed by the XL200
Series controller’s user interface.
Numeric Display Format
ID: 701
Selections: Decimal Inch / Feet-Fractional Inch / Feet-Decimal Inch / Decimal
Feet / Metric mm / Metric cm / Metric M
This parameter determines the format for displaying and entering all data values
with units of length. Examples of each format are shown below:
• Decimal Inch 126.500”
• Fractional Inch 10' 6-1/2”
• Feet-Decimal Inch10' 6.500"
• Decimal Feet 10.542'
• Metric mm3213.10mm
• Metric cm 321.310cm
• Metric M 3.213M
Auto-Delete Done Orders After
ID: 702
Range: 0 to 28 days
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This parameter determines how long complete orders remain in the controller’s
memory before they are automatically deleted. Orders & Items that have been run
to completion assume a status of Done. These records are automatically deleted
from the controller’s memory at either noon or midnight after the specified
number of days has elapsed. Of course the machine operator may delete these
records manually at any time.
Set Done Items to Ready
ID: 703
This parameter, when set to Yes’, causes the XL200 Series controller to
automatically re-program each line item as soon as it is run to completion. This is
useful for applications where the machine operator is not concerned with counting
the number of parts produced, but may simply be running the same part length
over and over again until his bin is full.
It is not recommended to enable this parameter whenever the controller is

networked with an Eclipse PC.
Enable Virtual Keyboard
ID: 704
This parameter, when set to Yes’, causes the XL200 Series controller to display
an on-screen virtual keyboard any time non-numeric data entry is required. The
virtual keyboard must be used to enter non-numeric (or alpha-numeric) data for
fields such as Order Numbers, Material Codes, Product Codes, and Coil Numbers.
If no non-numeric data is required or if an external PS/2 keyboard is attached to
the controller, the virtual keyboard may become an annoyance and can be
disabled.
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Figure 9: Virtual Keyboard
Velocity Display Unit ID
ID: 706
Range: 0 to 99
Applies to: Only when the Auxiliary Controller “S” model option is enabled
This parameter specifies Unit ID for a connected auxiliary controller if the

machine operator desires to view the velocity reported by the auxiliary controller
instead of the velocity calculated by the XL200 Series controller on the top line of
the display.
This is typically used on a specific machine configuration (roll-feed die-

accelerator combo) where the XL200 Series controller is controlling the roll-feed
portion of the machine, and the auxiliary controller is controlling the roll-former
and flying-cutoff portion. Often the machine operator is more concerned with the
roll-former velocity than with the roll-feed velocity.
See Also: Auxiliary Controller Operation
Show User Data – Program Screen
ID: 707
Selection: Disabled / One Line / Two Lines / Three Lines / Four Lines
This parameter allows the XL200 Series controller to display the user data fields
(optionally provided by the Eclipse PC) while in the Program screen. The
machine operator can choose to view none of this data, or up to 4 lines of data (2
fields per line).
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See Also: Eclipse User Fields
Show User Data – Status Screen
ID: 708
Selection: Disabled / One Line / Two Lines / Three Lines / Four Lines
This parameter allows the XL200 Series controller to display the user data fields
(optionally provided by the Eclipse PC) while in the Status screen. The machine
operator can choose to view none of this data, or up to 4 lines of data (2 fields per
line).
See Also: Eclipse User Fields
Show Help Preview – Setup Screen
ID: 709
Selection: Disabled / Enabled
This parameter allows the XL200 Series controller to display a help message
preview at the bottom of the screen while in the Setup Screen. The preview
contains the first sentence of two of the help message provided for each setup
parameter. The full help message text can be viewed at any time by pressing the
Help key.
Quickset Data
This menu provides a sub-set of other machine parameters that can be modified
by the machine operator at any time, regardless of the state of the Setup Lockout
input. The parameters have all been previously described in this chapter. The
Quickset Data menu is simply a convenient location to access some of the
parameters that are changed relatively often by many machine operators.
The parameters that appear in the Quickset Data list are shown below:
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Figure 10: Quickset Data Parameter List
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Chapter 7: Tool Data
Tooling Terms
The following definitions apply throughout this chapter:
Press
A press is a device that closes a die set that is to punch, notch or shear a given
material. Air, hydraulics, or a mechanical flywheel may power the press. The
Cutoff Press (Shear) is always considered press 0.
Tool
A tool is any section or combination of sections of a die set that can be engaged
with one cycle of a single press. The tool may produce a single hole, single notch,
group of holes, or notches, or cut the part completely.
Die Set
A die set is a mechanical assembly containing any number of tools that punch,
notch, or shear.
Gag
A gag is a device that can select or deselect specific tools in a die set. This is most
often a sliding block that is moved by an air cylinder prior to activation of the
press.
Pattern
A pattern is a set of tool operations that define most of the details of a finished
part. Each entry has a tool number, a reference designation, and a dimension. For
Y-axis machines, a Y-reference and Y-offset may also be necessary.
What is Tool Data

The Tool Data configuration lets the XL200 series controller know where all of
its tools are in reference to all of the others along with what output or outputs to

turn on for a given tool. The controller uses this information to calculate
when/where to turn on these outputs in order to make the desired part.
Note: For a machine that only cuts parts to length, the tool configuration is
very simple. Only one tool needs to be defined, for the shear. Every field in
the tool should be set equal to zero. See Defining a Tool.
Determining the Machine Zero Reference

Point
For each application, a Machine Zero Reference Point is required. It is usually
most convenient to use the shear blade as the zero reference point but it can be
any point that allows all measured offsets to be greater than or equal to zero. See
Figure 11.
Material Flow
ENCODER
PRE-PUNCH POST PUNCH CUTOFF
Figure 11: Press Reference Distance
This example uses the shear blade as the machine zero reference point. Tool
offsets can be measured by activating all dies, including the shear, with material
loaded and clamped in a stationary position. The strip is then fed forward past the
shear. The distance from the leading edge to the reference point on each die tool
can now be measured. These dimensions should be used as the X-offset value of
each tool.
Some machines may have tools that are downstream of the shear. In these cases,
the shear cannot be used as the reference point. Any convenient reference point
can be chosen that is even with or further down stream from the last tool. In this
case, the tool for the shear will have a positive offset from the arbitrary reference
point.
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1. Press [Setup] to display the setup menu selection list.

2. Highlight Tool Data, displaying the tool definitions in the right-hand window.
3. Press [F1] to tab over to the settings.
4. Press [F2]. A new tool entry displays below the currently selected tool entry.
The tool data display is shown in Figure 6-2. Each entry contains an ID, Press,
Gag, X-Offset, Y-Offset, Axis, and Name.
Figure 12: Typical Edit Tool Data Screen
Defining a Tool
Note: There must always be a tool to be defined for the shear. It must have
ID = 0 and Press = 0.
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ID (Tool Number)
The Tool ID field allows any numeric value from 0 to 974 or 0 to 649 depending
on your particular software model. Tools can be entered in any order and numbers
can be skipped.
Press
The PRESS number refers to the Press Output that should be activated by that
tool. The PRESS number must be from zero to the number of presses allowed by
the software model and configuration switches. Press 0 is defined to be the shear
press.
Gag
The GAG number corresponds to the Gag Output that is energized when this tool
is to be activated. If no gag is to be energized for a specific tool, the gag field
should be set to 0 (see Figure 12).
X-Offset
The X-Offset is a distance measured from the designated machine zero point to
the reference point of the tool. The X means that this measurement is in the same
plane as material movement, the X axis.
The reference point of the tool can be chosen as any part of the resulting feature it
places on the part.
Y-Offset
The Y-Offset is only used on tools that can be positioned automatically while the
line is running. The Y-Offset is measured in the Y axis plane (across the material
motion, X axis, plane). In most cases this value will be zero unless multiple tools
are all controlled in the Y axis by the same auxiliary device.
Axis
The AXIS field is only used on tools that can be positioned automatically while
the line is running. The AXIS is the ID of the Axis that a particular tool is
positioned in the Y axis by.
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Name
The Name is any 8-character name that may help the operator identify a particular
tool. Programming the NAME is optional.
Nested Tooling
If a single press has multiple dies that can be independently engaged using gag
valves, the user has the option of assigning different tool ID numbers to each
individual die tool. Each gag can then be independently engaged or disengaged
using a different tool number. However the operator is not limited to just one gag
per tool. Multiple gags may be used with the same tool. As an example, assume
that you have a press with three sets of tools on one Press (Figure 13).
PRESS
TOOL 1 TOOL 3 TOOL 2
GAG 3 GAG 4 GAG 5
Figure 13: Example Punch Press
With this tool arrangement, the following part can be made using the individual
tools in six punch press operations (see Example Part 1).
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Example Part 1
Many complex dies are designed to allow the tools spacing to coincide with
often-used patterns. This allows the press to create a usable pattern from different
tools in a single operation. If there are parts that can be made with some or all of
the tools during a single press operation (see Example Part 2), the pattern can be
programmed one of two ways.
1. First, the individual tools could be entered separately. In the example, this
would require three pattern entries for each press operation.
2. Second, all necessary tools that coincide on a press operation can instead be
assigned a separate tool number altogether. This would produce the same
operation but would reduce the programming step for this example to one per
press operation. If this is an often-used pattern, this could add up to a lot of
savings in programming time.
TOOL 3
Example Part 2
Example Part 1 can be made with Tools 1, 2, and 3. Part 2 could also be made
with Tools 1, 2, and 3, but the more efficient method would be to use Tool 4,
which includes all three tools.
An example of the Edit Tool Data screen is shown in Figure 14.
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Figure 14: Different Gags on the Same Tool and Press
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Chapter 8: Startup and

Calibration
Initial Tests and Settings
Wiring Verification
The wiring of the machine should be thoroughly checked for shorts and miss-
wires. Applying voltage to the controller’s inputs or AC voltage to the
controller’s outputs will result in a damaged controller and an unsuccessful
installation.
Powering the Unit for the First Time
It is recommended that a gradual power-up test be performed before beginning

the setup routine:
1. Disconnect the controller connectors (Connectors A – F) from the XL200CL
series controller and any other sensitive devices from their power sources.
2. Isolate the 110VAC supply from all input and output devices, power supplies,
and incoming 3-phase supply voltage. This may be as simple as setting the
power off/on switch to the Off position and removing the 110VAC
transformer input fuses.
3. Before applying and verifying the 3-phase power, check the Incoming 3-phase
power supply at its factory source to verify the correct voltage level.
4. Turn on the factory source (usually a disconnect or breaker) of power to the
console. Verify that the proper 3-phase power is present at the control
console.
5. Turn off the 3-phase input and reconnect the 110 VAC transformer to the
incoming 3-phase supply lines. Re-apply 3-phase power and verify that the
110VAC is at proper levels at the transformer output. Transformer taps that
are incorrectly connected could place low or high voltage across the system it
supplies, resulting in possible damage.
6. Turn the Power switch to On to connect the 110VAC supply to the
input/output devices. E-stop circuits may be able to be tested at this point also.
94

7. The 24VDC supplies should now be functioning. Measure the output voltage
of each supply and verify that they are at the right levels and polarity. Once
the installer is satisfied that all supplies are of the correct value and polarity,
the 110VAC should be turned Off.
8. Reconnect the controller connectors (connectors A – F) and all other sensitive
devices that were disconnected the first step.
9. Reapply power. The XL200CL series controller will power up. All systems
should now be functional.
Model Customization
The XL200 series controller can be set up to run in a variety of configurations

including punching or non-punching, flying cut or stopping cut, single speed or
dual speed, and with die boosts or without die boosts. For Models with multiple
punches, the number of punches and gags can be selected.
Refer to Error! Reference source not found. Error! Reference source not
found. (page Error! Bookmark not defined.), to locate the correct switch
configuration that best fits the specific application that the controller will be used
for.
Initial Setup Parameters
A thorough understanding of the parameters should be gained by reading Chapter

6:.Setup Parameters (page 43). Certain parameters will be reviewed in detail in
this chapter for the purpose of installing the controller and producing good parts.
After the controller has been properly installed and all wiring has been double-
checked, the basic controller parameters can be programmed.
1. Program the Shear Parameters:
A. Shear Dwell Down and Shear Dwell Up parameters.
AMS Controls controllers have a timed shear output with a switch input
override feature. The duration of the Shear Down output is programmable
from 0.001 to 30 seconds. Your Controller may have a Shear Boost output
or a Shear Up output. The Shear Boost output will be covered later in the
Flying Cutoff Calibration Section. The Shear Up output is programmable
with a range of 0 to 30 seconds. Refer to the timing diagram on Figure 15;
each parameter has a dwell time of .125 seconds.
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Figure 15: Timing Sequence of Shear Dwell Times
The controller has a Shear Complete input. If the controller detects a switch
closure on this input during the shear dwell down time, the dwell time is
overridden and the output will turn off immediately Figure 16.
This feature is especially useful on mechanical presses that require shear-

complete switch return the press to top-dead-center after every cycle. This is
simply done by adjusting the complete switch to the proper location on the
press. The Shear Dwell Up time is not affected by the Shear Complete input.
Note: On mechanical presses that do not have an electronic length

controller, a Shear unlatch switch is typically mounted as a rotating cam
switch or a dog-ear detector on the cam shaft. When retrofitting such a press
with an AMS Controls controller, these switches can usually be used as the
Shear Complete input. Care must be taken to isolate all power from the
contact points and the installer will have to change the contact closure
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Figure 16: Shear Output/Dwell Time Relationship
Note: If a shear-complete switch is used on a mechanical press, it

may need to be moved in order for the press to stop at the right location. If the
press stops short of top-dead-center, then move the switch so that it is
triggered later in the rotation. If the press stops late (beyond top-dead-center),
move the switch so that it is triggered earlier in the rotation.
Set the shear dwell times to an approximate value. Large mechanical presses
may require .5 seconds or more. Air presses may only require .020 to .040
seconds to complete a cut. Fire the press by using the manual cycle input and
adjust the shear dwell times until the press operates properly. If the press does
not fire completely, make the dwell time longer. If the press hits too hard or
stays on too long, make the dwell time shorter.
B. Program the Expect Shear Complete parameter.
The Expect Shear Complete setup parameter can be set to Yes or No.
Setting the parameter to Yes enables a test feature that will inform the user
if the Shear Complete input or switch has failed. The controller will
expect to see the Shear Complete input to turn on at some point during the
Shear Dwell Down time or it will exit the run mode, terminate the press
cycle, and inform the user that the controller did not see a press complete
input.
C. Program the Expect Shear Up Complete parameter.
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The XL266 controller has a setup parameter performs the same function as
the Expect Shear Complete except that it has and tests for a Shear Up
Complete input during the Shear Dwell Up time. The Shear Up Complete
input overrides the Shear Up Dwell just like the Shear Complete input
does to the Shear Dwell Down time. Setting Expect Shear Up Complete to
Yes enables a test feature that will inform the user if the Shear Up
Complete input or switch has failed. The controller will expect to see the
Shear Up Complete input to turn on at some point during the Shear Dwell
Up time or it will exit the run mode, terminate the press cycle, and inform
the user that the controller did not see a press up complete input. An
additional function of turning on the feature enables a test that prevents
the controller from entering the run mode if the Shear Up Complete input
is not on. This will minimize material jam ups and damage to the machine
or personnel.
2. Program the Press Dwell parameters (each Press will have similar,
corresponding, setup parameters, inputs and outputs, to the Shear):
D. Press Dwell Down and Press Dwell Up parameters:
AMS Controls controllers have a timed press output with a switch input
override feature. The duration of the Press Down output is programmable
from 0.001 to 30 seconds. Your Controller may have a Press Boost output
or a Press Up output. The Press Boost output will be covered later in the
Flying Cutoff Calibration Section. The Press Up output is programmable
with a range of 0 to 30 seconds. Refer to the timing diagram on Figure 15;
each parameter has a dwell time of .125 seconds.
E. Expect Press Complete
The Expect Press Complete setup parameter can be set to Yes or No.
Setting the parameter to Yes enables a test feature that will inform the user
if the Press Complete input or switch has failed. The controller will expect
to see the Press Complete input to turn on at some point during the Press
Dwell Down time or it will exit the run mode, terminate the press cycle,
and inform the user that the controller did not see a press complete input.
F. Expect Press Up Complete
The XL266 controller has a setup parameter performs the same function as
the Expect Press Complete except that it has and tests for a Press Up
Complete input during the Press Dwell Up time. The Press Up Complete
input overrides the Press Up Dwell just like the Press Complete input does
to the Press Dwell Down time. Setting Expect Press Up Complete to Yes
enables a test feature that will inform the user if the Press Up Complete
input or switch has failed. The controller will expect to see the Press Up
98

Complete input to turn on at some point during the Press Dwell Up time or
it will exit the run mode, terminate the press cycle, and inform the user
that the controller did not see a press up complete input. An additional
function of turning on the feature enables a test that prevents the controller
from entering the run mode if the Press Up Complete input is not on. This
will minimize material jam ups and damage to the machine or personnel.
3. Program the Resolution parameter.
The Resolution parameter informs the controller what each pulse from the
material tracking encoder represents in length. If this value is off by even a
slight degree, all subsequent measurements will be proportionally off during
operation of the controller.
Note: This parameter must be input before any kind of testing is

performed.
To calculate Line Resolution, divide the circumference of the encoder wheel

by the number of PPR (Pulses per Revolution) of the encoder.
• The circumference of the wheel is determined by measuring the

diameter of the wheel and multiplying that number by pi (3.1416).
• The PPR (pulses per revolution) is determined by multiplying the rated
number of encoder counts by 4. The model number of an AMS
Controls encoder represents the number of counts from one channel of
that encoder.
For example, a 256-count encoder will provide 1024 PPR. Similarly, a 500-
count encoder will provide 2000 PPR. Refer to the following formula.
Circumference
Resolution =
4 x Encoder Counts
For example, suppose a wheel 5.0 inches wide is mounted onto a model 1000
encoder. The formula shows how the resolution is calculated.
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5.00 in. × 3.1416 15.708

Resolution = = = .00393
4 x 1000 count 4000
Test the E-stop Circuit

Before testing any functionality of the controller or machine, the Emergency Stop
and Safety Circuits should be tested for proper operation. Not only may this save
injury to personnel, but it may save equipment and material from getting
damaged.
If the Emergency stop circuit is a latched circuit, make sure that it latches
properly and that the latch is dropped by the loss of any E-stop button or other
emergency stop switch, safety curtain, or other device.
1 DANGER! Although AMS Controls provides wiring templates and

wiring methods for customers use, each customer is responsible for
designing, installing, and applying an adequate emergency stop
circuit as well as necessary safety guards and enclosures for the
protection of personnel and equipment!!
When an emergency stop condition occurs, all output devices should be isolated
from their power source. However, the AMS Controls CPU power (Terminals A1
& A2) should only lose power when the controller is turned off via a power
switch. The controller’s encoder input and DC inputs can still be active during an
e-stop condition, and the display diagnostic information may assist the operator in
the case of a problem.
1 DANGER! Special care should be taken to ensure that an E-Stop

condition unlatches all input circuits to prevent any automatic
movement or functionality of the machine or controller from
occurring after the E-Stop circuit is reset.
Test Inputs and Outputs
Test Jog outputs
The jog inputs and motion outputs should be tested for proper operation and
direction. If the outputs do not energize properly, the XL200 series controller has
an input/output screen with which to view the states of the inputs and outputs.
100

This window is available through the Diagnostic screen of the controller and
provides a handy means for troubleshooting.
Jogging forward should result in the material feeding device moving in the
forward direction. Two speed machines should provide outputs for the slow
velocity. Jogging reverse should provide the opposite feed at slow speed.
Test Encoder Direction
Initiating the jog forward input should cause the material feeding device to go in
the forward direction. If material is in the machine, the material position on the
controller should grow more positive. Keep in mind that the number may be
growing but in the negative direction. If the controller counts more negative while
jogging forward, the parameter for Encoder Direction will need to be reversed.
The choices are CW and CCW (Clockwise and Counter-Clockwise)
Test Shear Outputs
The press dwell time is simply set by manually cycling the press and adjusting the
Shear Dwell Down and Up times until the press makes a full and complete cut.
Large mechanical presses may require between .2 to .5 seconds typically. Air
presses may only require 40 to 80 milliseconds (.040 to .080) to complete a cut.
Initiate the manual shear input to fire the press and adjust the shear dwell times
until the press operates properly. If the press does not fire completely, make the
dwell time longer. If the press hits too hard or stays on too long, make the dwell
time shorter.
If a shear-complete switch is used on a press (usually mechanical presses) it may

need to be moved in order for the press to stop at the right location. If the press
makes less than a full rotation (short of top-dead-center), move the Shear
Complete switch so that it is triggered later in the cycle. If the press over-rotates
(beyond top-dead-center), move the switch so that it is triggered earlier in the
cycle.
Initial Run & Calibration
Once the basic parameters are set and the emergency circuits are tested, the
controller can be tested to see if the run input and run output are properly
connected. The basic purpose of the test is to verify that the run circuit will latch-
in with a Line Run command and un-latch when Line Halt is signaled. This is best
done without material present in the machine.
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Program a basic order of a given length. Use no patterns, materials, or other

options, just a length such as 5 pieces at 72 inches. If possible, turn the line speed
down to a slow feed. Initiate the run input. The run latch should turn on and hold
the unit in a run state. The motion outputs should energize and begin feeding in
the forward direction (with or without material). Press the halt button to verify
that a manual halt will stop the line.
Initiate the run input again. If no material is loaded and it is safe to do so, turn the
encoder wheel by hand in the forward direction to simulate material motion. If
setting up a feed to stop line, the Tolerance parameter may need to be increased to
a large value such as 10.000 inches to allow a non-steady hand to avoid tolerance
errors when stopping at the programmed target distance. After the last part is
made, the run latch should open, causing the run input to drop and the motion
outputs to disengage.
The controller should now be ready for the initial run. The system can then be
calibrated using the specific parameters for a flying-cutoff or a feed-to-stop. Each
type of controller is setup in the next two sections.
Flying Cutoff Calibration
What is Shear Reaction?
Shear Reaction Time is the amount of time that it takes a press die to move from
its rest position (once fired) to the point at which it impacts the material. This
time lapse is a result of an accumulation of delays due to energizing relays &
solenoids, filling cylinders with air or hydraulics, and the overcoming die inertia.
Without compensating for these time lapses the actual shearing operation would
be displaced from the desired cut point (Figure 17). By using the proper shear
reaction time, the controller can more accurately cut on-target, most noticeably on
the first piece made after a standing crop.
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TARGET ACTUAL CUT
Figure 17: Delay Reactions that add up to the Shear Reaction
As Figure 17 shows, the delay reaction is actually caused by several factors. In

this case the Shear Reaction is the accumulation of delays A, B, C, D, E, and F.
This causes the press to lag behind the target. If not compensated for, every piece
made will include a similar amount of error.
Each piece has an equal amount of error if the line velocity and reaction delays
remain constant; therefore parts appear to be good as long as conditions stay
identical. If any of the reactions vary or if the speed of the material fluctuates
even slightly from one cut to the next the resulting lengths will vary. For most
pneumatic and hydraulic presses, the delay time is usually constant. Sometimes
these constants drift over time due to heat, humidity, moisture, and friction
variations. The result is loss of tolerance. Velocity variations on the material feed
are common and are also a source of inaccuracy on flying die machines. The
reason the first piece after a standing crop is the most noticeably affected by
Reaction Time is because the change in velocity between the standing leading
edge crop and the moving trailing edge crop is the greatest.
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Figure 18: Timing Graph of Shear Reaction Time
Ì Caution: A Shear Reaction time that is larger than the Shear Dwell time
is unrealistic, as it would cause the shear completion time to occur prior
to the target coincidence.
Note: A Shear Reaction time turns on the shear output prior to the target
coincidence point. It does not affect Shear Dwell.
Setting Shear and Boost Reaction Times
Note: Before attempting to perform the procedures detailed in this section,

the Trim Correction procedure at the end of this chapter should be performed.
This will ensure that all of the calculations involved in this section will be as
accurate as possible.
Note: The procedures in this section should be performed from beginning to

end in order to finish with a predicable result.
Shear Reaction is necessary on flying cut lines because of delays that occur
during the shear cycle. These delays occur due to the time it takes for valves to
energize, cylinders to fill, and for dies to move. Since the Shearing function is not
instantaneous, the shear must be activated prior to the actual cut point, see Figure
19.
104

Figure 19: Shear Reaction vs. Actual Cut Point
To calculate the Shear Reaction time,

1. Set the Shear Reaction time to zero
2. Cycle the shear
3. Run two parts that are long enough for the line to reach full velocity before
firing the press.
4. Note the line speed on the controller display (Top, Center)
5. Mark the parts 1st Part and 2nd Part.
6. Use the following formula for the new Shear Reaction time:
⎡ (1st Part - 2nd Part ) ⎤

Shear Reaction Time = ⎢ ⎥×5
⎣ Line Speed in FPM ⎦
105

Setting Shear Reaction with a Boost attached
Boost cylinders and boost reaction can cause problems when trying to calculate
shear reaction time. See the following example
Figure 20: (Example) Boost displacement of die vs. target coincident point
Notice that the die boost does not change the shear reaction itself, but it can cause
the die to fire in a different location since the entire die is moved forward during
the cut.
If possible, disconnect the die boost when setting shear reaction. This will allow
you to use the above method for calculating the Shear Reaction time. Although
you may have to run the line at a slower speed, this is the quickest and most
accurate way of setting the shear reaction.
Another way to figure shear reaction with a boost is to test at two different speed
ranges. For example, perform the standard reaction test at 100 FPM and then
again at 200 fpm, and then calculate the difference in the two speeds and the two
errors to set your reaction times (the theory is that the boost compensation
distance of the die is a constant value, but the shear reaction error will grow
lineally as the line material moves faster).
106

For example, with First Speed At 100 FPM (20 In/Sec)
• Crop the leading edge of the material and run part #1.
• Part is 120.90 inches long
Then with the Second Speed At 200 FPM (40 In/Sec)
• Crop the leading edge of the material and run part #2.
• Part is 121.80 inches long
The difference in speed is 100 FPM (20 In/Sec)
Now apply the shear reaction formula
Part 2 − Part1 121.80" − 120.90"

× (5) = (5) = .045 Re action Time
SecondSpeed − FirstSpeed 200FPM − 100FPM
Boost Reaction Time
Many dies have a boost cylinder attached to them to push the die forward with the
material. This causes less stress on the material as the die tool engages it.
Optimally, the die would be moving at the same speed as the material for best
cutting results.
Note: Always keep in mind that the Boost Reaction is only for enhancing the
quality of the cut, not for correcting the length of the part.
There are no formulas for calculating boost reaction times. It basically comes
down to two rules:
• If you are buckling or damaging the leading edge of cut or punch during the
press operation, increase the boost reaction in order to cause the die to push
forward earlier in time allowing the die to be moving faster at the cut point.
• If you are pulling or tearing the material during a punch or cutting operation
the die is going faster than the material. Decrease the boost reaction time to
cause the die to be moving slower at the cut point.
The Shear Boost Dwell sets the length of time that the Die Boost Output stays on.
The Die Boost output is activated at the target coincidence point and left on for
the value of time programmed into the Shear Boost Dwell time (Figure 21). This
is done to push the die forward in order to allow the shear press to cycle through
the material without damaging the part.
107

The Die Boost Reaction time turns the Die Boost on earlier in time. This allows
the die to begin accelerating prior to the target coincidence point; allowing for the
press to more closely match the line speed before the die tool hits the material.
Figure 21: Die Boost Timing
When the Die Boost Reaction is added, the Die Boost output is advanced earlier
in time as referenced to the Target Coincidence (See Figure 22). The reaction
time shifts the entire pulse forward in time.
Note: The Die Boost Reaction Time is entirely independent of Shear

Reaction Time. Die Boost Reaction is typically greater than or equal to the
Shear Reaction.
108

Figure 22: Die Boost Timing with Shear Reaction
If the leading edge of the part gets caught on the die (pushes the die), the Shear
Boost Dwell time should be increased. If the die moves too far out causing the
material to pull or tear, the Shear Boost Dwell time should be decreased.
Boost Compensation
The final step of calibrating the Shear should be setting the Boost Compensation
parameter. After the Shear Reaction time has been calculated by one of the two
methods above, the first piece after a manual shear may still be short due to the
Boost Comp. Dist. (see Figure 20). Setting the Boost Compensation parameter
equal to the difference between the first part and second parts after a standing
crop cut should resolve this issue by adding this distance to the first part.
Note: Any changes to the Boost or Shear Reaction times may require changes
to this parameter as well.
Press Reaction Time (Short Distances)
Note: Prior to using the procedure to calculate the Press Reaction, the
Correction Factor and Shear Reaction should first be calculated.
The Press Reaction time is the time delay that takes place between the time that
the punch signal occurs and the time that the die contacts the material. This factor
is used on flying die machines only. The maximum value is 1.000 seconds. There
is a Press Reaction time for each Press.
Calculate the Press Reaction time using the following steps:

1. Set the Press Reaction time to zero
2. Program a 130" part with holes at 60" and 120". This may need modification
to assure that the line is up to full speed before the first punch occurs.
3. Cycle the shear
4. Run the line
5. After the first part is cut, jog the material out and measure the leading edge to
the first hole and the first hole to the second hole
6. Use the following formula for the new Press Reaction time:
109

Press Reaction Time (Long Distances)
If there is a long distance between the shear and the press and a large amount of
scrap would be produced, the following procedure could be used:
Calculate the Press Reaction time using the following steps:

1. Set the Shear-Punch Distance and the Press Reaction time to zero
2. Program a 130" part with holes at 60" and 120"
3. Cycle the Shear and the Press being tested.
4. Run a single part.
5. After the first part is complete, measure from the manually produced hole to
the first hole and the first hole to the second hole
6. Use the following formula for the new Press Reaction time:
⎡ (MH to 1st Hole) − (1st to 2nd Hole) ⎤

Press Reaction = ⎢ ⎥×5
⎣ Line Speed ⎦
MH =Manually Produced Hole
Both methods will calculate a good press reaction time. This same test must be
repeated for all individual presses.
Feed-to-Stop Setup
Minimum Slow Distance (2-speed lines only)
The Minimum Slow Distance is the value used by the controller to determine how
close to the end of the part that the controller shifts its outputs from fast speed
logic to slow speed logic. The larger this value is, the sooner the line will shift
into a slow velocity (creep speed) prior to press operation. This parameter needs
to be set large enough so that the line is in the stabilized slow velocity before the
controller tells it to stop for the operation. If this parameter is too small, the
material may still be decelerating from the fast speed when it is told to stop,
thereby producing poor tolerances.
110

This parameter is used in conjunction with the Deceleration Factor parameter.

When the Deceleration Mode parameter is set to automatic or manual, an
additional slow down length will occur depending on line speed and machine
operation.
Deceleration Mode (2-speed lines only)
On two-speed machines, the XL200 Series uses a Deceleration (Decel) Factor

when changing from fast to slow speed. The Decel Factor is used in conjunction
with the Minimum Slow Distance to determine the ideal time to shift from fast
speed to the slow speed. The user has the options:
Auto
The XL200 Series controller automatically maintains and updates the

Deceleration Factor parameter. 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 is automatically updated during the next speed shift or stop.
Manual
This allows the Deceleration Factor to be manually entered into the controller
rather than being automatically updated. Some trial and error may be necessary
when in the Manual mode to find a Decel Factor that works properly. Ideally, the
machine should shift from fast to slow at some distance prior to the target (shear
or punch point) and long enough so that it reaches a constant slow velocity before
the motion outputs are turned off.
If the machine tends to shift into slow too soon, increase the Decel Factor. If the
machine tends too shift into slow too late, decrease the Decel Factor.
While in the Manual mode, the XL200 Series controller will not calculate a new
value for the Decel Factor after each speed shift or stop.
Off
The Deceleration Factor is not used and the controller will not make an Adaptive
Slowdown calculation. The machine will shift from fast to slow when the material
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 four inches before each press operation. This may or may not be
enough distance for the machine to decelerate properly.
111

The Deceleration Mode defaults to Off. Setting this parameter to Manual or Auto
may increase productivity by running the line in slow for the minimal amount of
time necessary.
Deceleration Factor (2-speed lines only)
A Decel Factor can be set to keep production optimized by minimizing the

amount of time that the material is running in slow speed. Like the Stopping
Reaction, the Decel Factor can be set manually, automatically or turned off in the
Decel Mode parameter. When set to Automatic, the controller will continually
calculate and adjust the optimum point at which to shift the line into slow speed
so that material is moving at a steady, slow velocity just as it reaches the
Minimum Slow Distance before the target.
If the Deceleration Factor is set to Off the controller will use only the Minimum
Slow Distance when determining the location to change the feed rate to a slow
speed. The Decel Mode may also be set to manual. This will allow the operator to
program the Deceleration Factor by hand. In this case the parameter will not be
automatically updated and the controller will not make any adjustments for
changes in line performance.
The controller with Adaptive Slowdown uses the measured line speed and
deceleration characteristics of the machine to calculate the optimum point to shift
into slow speed. The result (Figure 23) is less time spent in slow speed on short
parts, which leads to increased productivity. The XL200 Series controller
continuously monitors machine parameters and automatically adjusts for machine
changes.
Speed Distance
Long Move
Short Move
Slow Slow
Length Length
Figure 23: Speed Profile with Adaptive Slowdown
To increase productivity, on stopping lines, the controller will fire a shear or

punch upon reaching a halted velocity. This halted velocity will allow a specific
112

number of encoder counts to occur and still be considered halted. This allows the
press tool to meet the metal just as it stops moving. The controller waits until
tolerance is reached, then checks for the material to fall below halted velocity at
which time it can fire the shear. This speed is calculated based on tolerance and
shear dwell time. To calculate the halted velocity, use the following equation:
“T”/”D”= 5(“S1”)= “S2 FPM”
Where:
S2 = Line Speed in Feet Per Minute
S1 = Line Speed in Inches Per Second
T = Tolerance in Inches that is Programmed into the
Tolerance Parameter
D = Dwell Time of the Press in Seconds that is Programmed into the
Shear Dwell or Press Dwell Parameter
To force the controller to use a smaller halted velocity, make the tolerance
smaller.
Tolerance
The Tolerance parameter sets the acceptable measurement range the controller
will be allowed to stop within in order to perform an operation.
If the controller stops for a press operation but detects that the target is further
away from the target point than what the parameter is set to, the controller will
not cycle the press.
If the target is missed by more than the Tolerance value, it will halt the line and
post a warning to the operator that the part is Out of Tolerance.
This parameter should be set low enough that parts are within a window of
acceptance, but large enough not to get repeated errors.
For example, suppose a 120-inch part is produced with a programmed Tolerance

of .125 inches. If the controller stops for the operation and the target is between
119.875 and 120.125 inches, the controller will cycle the press and continue
running. Anything thing outside this quarter-inch window (+/- .125) will cause
the controller to halt and post the error.
Note: The Tolerance parameter may need to be set to a larger value (3 or 4

inches) initially while calibrating the machine for the first time. Once
calibration is complete, set the parameter for the required production value.
113

Stopping Mode
On feed-to-stop machines, a Stopping Reaction time parameter is used. This

represents the time delay from the time that the controller turns off the movement
outputs until the material actually stops. The longer a machine takes to stop, the
larger the reaction time will need to be. Knowing that the machine will require
time to stop, the value from this parameter is used to stop the material before
reaching the press target. The user has a choice of three Stopping Modes :
Auto
The XL200 Series controller turns off the movement outputs prior to the actual
shear or punch point, allowing for the momentum and inertia of the machine and
material to carry it to the correct stop point. The stopping reaction is monitored
continually with a new STOPPING REACTION time being calculated after each
operational stop. This parameter may be overridden in the Manual Calibration
mode but the value will be again be updated after the next operational stop. A
tolerance check will be performed before firing the shear. The maximum value is
5.000 seconds.
The default mode for Stopping Reaction time is Auto. This is the recommended
mode of operation.
Manual
This mode functions identically to Auto except that a new Stopping Reaction is
not calculated after each stop. The controller will use the manually entered value.
Off
The value in the Stopping Reaction parameter is not calculated and is not used at
all by the XL200 Series controller. The movement outputs are turned off when the
material past the shear point is equal to the programmed length of the part. This is
the least accurate mode and may cause all parts to come out long due to the
momentum of the machine and material during stopping. When the Stopping
Mode is set to Off a tolerance test is not performed.
Stopping Reaction
What is Stopping Reaction?
Feed-to-stop machines are used instead of flying die machines because the dies
are simpler and the machines are normally more accurate. Higher accuracy is
114

normally achieved by slowing the line speed down to a creep speed just before the
target. This is done to minimize the effect of a delay in stopping that occurs and to
increase consistency when the stop signal is given by the controller.
Similar to the flying die situation, it takes a finite amount of time for valves to
close, brakes to engage, and motors to stop turning. With simple counters, an
overshoot past the target always occurs. Shifting into slow speed minimizes the
amount of overshoot.
DISTANCE OF ERROR
DUE TO DELAY IN
MATERIAL STOPPING
TARGET
ACTUAL STOP POINT
Figure 24: Feed-To-Stop System Showing a Delay In Stopping
If the delay time and slow speed are constant, the lengths are often consistent, but
lack true accuracy.
The XL200 Series controller improves the performance of feed-to-stop machines

by compensating for the stopping delay time and automatically setting the
slowdown distance.
The controller uses its automatic parameters to calculate an advanced target to

stop the machine so that it coasts into the exact shear point.
115

The controller measures the amount of overshoot or undershoot on each move and
adjusts the Stopping Reaction Time to match the characteristics of the machine.
The user can specify a tolerance so that accuracy is assured.
For example, suppose you have a motor driven Feed Roll with a clutch/brake
assembly running a line. The motor runs continuously and the clutch is engaged
to put the material into motion. When the line is halted, the clutch is released and
the brake is engaged to stop the line.
Several causes can delay the line from halting immediately.

• The momentum of the Rolls and of the material can continue feeding forward
for a short duration after being disengaged.
• The time it takes to energize the solenoid valves that control both the brake
and the clutch.
• The brake overcoming its inertia and a distance before engaging the rolls to
stop them.
• Slippage between the roll pad and the brake pad after the brake engages.
The XL200 Series controllers are programmed to handle this problem of

overshoot automatically. The Stopping Reaction Mode and Stopping Reaction
Time are in the Machine Parameters of the XL200 series controllers.
The controller knows where the target is located via the line encoder. At the
precise moment that the target is below the shear blade, the controller attempts to
halt the line. Due to the reasons mentioned above, the target will coast a little
further before it stops.
The controller senses (through encoder measurement) that the target is past the
blade by given measurement. It knows that it was X inches away from where it
should have been. It then uses a proprietary algorithm to calculate a reaction time
to correct for the overshoot. In order to minimize issues with machines that have
inconsistent stopping reaction times the controller does not correct for the full X
error amount every time but finds an average value that it adjusts over several
parts.
Note: During a new installation or a recalibration, it is recommended to run

at least 7-10 short parts to allow for the automatic calculation of the Stopping
Reaction time. This will allow it to reach its stable range. It is advisable to set
the Tolerance parameter to a larger value until the stopping reaction parameter
is stabilized.
The Stopping Reaction can be set manually, automatically or completely turned

off through the Stopping Mode parameter. When set to automatic, the controller
will compare the intended target position to the where the target actually stopped.
116

The two positions should vary initially due to coasting of the material after the
controller turned off its feed outputs. The error between the two positions will be
integrated out over the next few parts. Since the first few parts may be
substantially off-target until the reaction time is worked out, it may be best to set
the Tolerance parameter to a larger number.
If the target stops outside the range programmed into the Tolerance parameter, the
controller will automatically turn off the run output without firing the shear and
post an error message on the display.
Once the Stopping Reaction Time is calculated, the Tolerance parameter can be
set back to the required level. As long as the Stopping Mode is set to automatic,
the controller will continually update any for any variations in how long the drive
system takes to stop the line.
The Stopping Reaction Time can be manually set if manual is selected in the
Stopping Mode. Manually entered settings in this parameter will not be
automatically adjusted for if changes in the operation of the line occur. These
parameters will be found on both single-speed and two-speed applications.
Inducing Automatic Values
Once the basic Configuration parameters and Manual Calibration parameters are
set, you can begin to run the line and calibrate the lengths.
Initial Run
Widen the Tolerance parameter to allow for calibration of the Stopping Reaction
time. This may need to be several inches.
Set Minimum Slow Distance to a value conservatively larger than the distance it
will take the material to shift from fast speed to a stable slow speed.
Program some short parts from 36 to 60 inches. Put the controller into run and
watch the display. As each part is cut, the amount displayed as being cut should
get closer to the actual programmed length. This is due to the automatic features
of Stopping Reaction and Decel Factor. If these are not set to automatic they must
be set by hand using trial and error.
If the Stopping Reaction Mode is set to Automatic, Watch the Stopping Reaction
until it becomes a relatively stable value.
If the Deceleration Mode is set to Automatic, the line may shift into slow mode
very early in the part during the first few pieces made. This will gradually become
closer and closer to the Minimum Slow Distance parameter. Watch the Decel
117

Factor until it becomes a relatively stable value. Once it has become stable you
can shorten the Minimum Slow Distance to a smaller value. The Minimum Slow
Distance must be larger than the distance it takes the material to stop from slow
speed. If set to too small a value it can confuse the Stopping Reaction calculation
and cause tolerance problems.
Now measure the sample that you just produced. You should notice that the first
parts (probably long) eventually were corrected for and that the last parts are a
relatively consistent length.
Once the parts appear to be consistent (even though they may appear to be
slightly shorter or longer than the target), you can move onto setting the
Correction Factor.
Trim Correction
The Correction Factor adjusts for errors in the size and tracking of the measuring
wheel and is expressed as a percentage, with 100% being no correction.
Increasing the Correction Factor causes the parts to become longer and decreasing
the value shrinks the parts.
The XL200 Series controller’s Trim Correction feature automatically computes a

new Correction Factor. The Correction Factor is used in the controller’s length
calculations. Trim Correction should be used any time part lengths are incorrect
in a consistent manner (e.g., all parts 3/16 long, etc.).
The XL200 controller provides an easy method for making such corrections.
Press the Setup button on the controller and highlight Trim Correction. The
window to the right will display the Last Programmed Length, Last Measured
Length, and the Correction Factor.
Note: When calculating the Correction Factor, make several parts (6 to 10)
and use the average of these parts for the part length. The first part produced
should not be used in this calculation since it may be inaccurate due to shear
reaction, boosts motion, or other variances.
118

Figure 25: Trim Correction Window
The Last Programmed Length automatically displays, assuming that this is the
length that is being corrected for. The Length displayed here can be edited to a
different length for a part previously produced and the correction is adjusted
according to the new value.
If a correction is desired, press [F1] to tab to the parameter window on the right
side of the screen. Highlight the Last Measured Length field and input the actual
part length being measured. Remember, it is best to take an average of the lengths
being produced and input the averaged length in order to get the best results.
Once the length is Input, press [Enter]. A popup window displays and prompts the
user to accept the new correction factor. Select [Yes] to accept the correction, or
[No] to cancel it.
119

Figure 26: Update Correction Popup Window
As discussed in the Startup and Calibration chapter, the Correction Factor may
also be manually calculated using the following steps:
1. Run ten parts of equal lengths, 120" for example.
2. Measure the ten parts.
3. Find the average length by adding up all ten parts (the last eight parts if Shear
Reaction has not been set) and dividing by ten (eight if Shear Reaction is not
set).
4. Use the following formula for the new Correction Factor. Use the average of
the ten parts for "actual measured length."
⎛ Programmed Length ⎞
New CF = ⎜ ⎟ × Old CF
⎝ Actual Measured Length ⎠
Note: CF = Correction Factor
120

Appendix A: Specifications
Mechanical Specifications
Mounting
Size 11" high x 12.375 wide x 4" deep
including cable
Weight 7lbs
Figure 27: Side Dimensions of the XL200
121

Figure 28: XL200 Cutout Dimensions
Only the dotted line in Figure 28 is to be physically cut out. The outer box
displays the actual coverage of the front panel.
Make sure to clean the cutout material to be free of metallic debris that could later
drop into the controller and potentially cause problems.
Electrical Specifications
CPU Input Power
Input Voltage 24VDC ±10%
Continuous Power Consumption 20 Watts
Inrush Current 5 Amp
Recommended Supply 2.5 Amps (60 Watts)
Input Characteristics
Green Connectors (Standard) Current Sourcing
122

Black Connectors Current Sinking
Output Characteristics
Green Connectors (Standard) Current Sinking - Per input (3.5 DC amps
continuous, 9 amp 100ms pulse) Per Fused
Bank (3-9 DC amps, depending on
installed fuse)
Black Connectors Current Sourcing - Per input (3.5 DC amps
continuous, 9 amp 100ms pulse) Per Fused
Bank (3-9 DC amps, depending on
installed fuse)
Encoder Input
Type Quadrature with Complements (differential)
Voltage Supplied 5VDC
Maximum Encoder Load 200 milliamperes
Maximum Pulse Rate 200,000 pulses/second
Analog Output Characteristics

Type Differential Line Driver
Maximum Range +/- 10 Volt Bipolar Output
Communication Port Characteristics

Port A RS485
Port B RS485
Port C RS485/RS422
Port D RS485/RS422
123

124

Appendix B: Diagrams
Wiring Diagrams
Generic wiring diagrams have been provided in order to give the installer an idea
of how each system is to be wired. Adequate safety circuits and guards must be
added to any installation
For details on inputs and outputs, see Input/Output Definitions, page 14
a WARNING! AMS Controls provides the following drawings for

illustration purposes only. They are not to be taken as literal examples
for wiring machinery. Every machine is different and has its own safety
considerations.
a WARNING! The customer is responsible for the installation of adequate

emergency stop circuitry, safety guards, and the enclosure of all
equipment that is potentially hazardous to personnel.
125

CPU GND CPU 24VDC

CPU
CUSTOMER IS RESPONIBLE FOR INSTALLING

ADEQUATE SAFETY DEVICES AND GUARDS
FOR THE PROTECTION OF PERSONNEL
AND MACHINERY.
Figure 29:XL200 Main Diagram
126

I/O GND I/O 24VDC

I/O BIAS

AND MACHINERY.
Figure 30: XL200 Sink Diagram
127

I/O GND I/O 24VDC

I/O BIAS

AND MACHINERY.
Figure 31: XL200 Source Diagram
128

Appendix C: Worksheets For

User-Recorded Parameters
Controller Information
Serial Number:
Version Number:
Switch:
Note: Use this sheet to fill in the machine setup values. This list includes all
possible parameters and not all controllers have every parameter. Only fill in
the values for your machine. Use the switch drawing to show your switch
setting.
129

Machine Parameters Sheet

Machine Parameters
Shear Dwell Down

Shear Dwell Up
Shear Boost Dwell
Shear Reaction
Shear Boost Reaction
Shear Boost Enable Velocity
Expect Shear Complete
Expect Shear Up Complete
Press 1 Dwell Down
Press 1 Dwell Up
Press 1 Boost Dwell
Press 1 Reaction
Press 1 Boost Reaction
Press 1 Boost Enable Velocity
Expect Press 1 Complete
Expect Press 1 Up Complete
Press 2 Dwell Down
Press 2 Dwell Up
Press 2 Boost Dwell
Press 2 Reaction
Press 3 Dwell Down
Press 3 Dwell Up
Press 3 Boost Dwell
Press 3 Reaction
130


Press 4 Dwell Down
Press 4 Dwell Up
Press 4 Boost Dwell
Press 4 Reaction
Press 5 Dwell Down
Press 5 Dwell Up
Press 5 Boost Dwell
Press 5 Reaction
Press 7 Dwell Down
Press 7 Dwell Up
Press 7 Boost Dwell
Press 7 Reaction
Press 8 Dwell Down
Press 8 Dwell Up
Press 8 Boost Dwell
131

Press 8 Reaction
Press 9 Dwell Down
Press 9 Dwell Up
Press 9 Boost Dwell
Press 9 Reaction
Press 10 Dwell Down
Press 10 Dwell Up
Press 10 Boost Dwell
Press 10 Reaction
Press 11 Dwell Down
Press 11 Dwell Up
Press 11 Boost Dwell
Press 11 Reaction
Tool Selected for Manual Punch
132

Bundle Quantity Reload Value

Bundle Quantity Count
Item Complete Output Duration
Delay After Shear
Minimum Slow Distance
Scrap Part Length
Halt Mode
Halt No More Items to Run
Stopping Reaction Mode
Deceleration Mode
Deceleration Factor
Tolerance
Alternating Press Mode
Stitch Gag
Max Auto Stitch Length
Slow Output While Halted
Stacker Dwell
Stacker Delay
Parts Per Stack
Expect Stacker Complete
Horn Dwell
Crash Detect Velocity Change
Crash Detect Time
Test Part Length
Use Coil Inventory
Allow Coil Override
Bump Tolerance
Bump Time
Coil End Point

Coil End Offset
133

Encoder Direction
Shear Kerf
Minimum Part Length
Shear to Encoder Distance
Machine Material Y Reference
Enable Multi-Angle Shear
Clear Queue After
Enable Shear Encoder Distance 2
Shear to Encoder Distance 2
Coil Trim Cut Distance
Front Shear Tool
Front Shear Advance
Hole Mode Select

No Hole Stop Distance
Hole Detect Logic
Minimum Hole Spacing
Shear to Detector Distance
Hole Tolerance
Line Resolution
Velocity at Max Analog Voltage
Auxiliary Shear Compensation
Boost Compensation
Filter Constant
Minimum Speed Voltage
Maximum Speed Voltage
Length at Maximum Speed
Jog Speed Voltage
Correction Factor
134

Time Format
Date Format
Date Separator
Network Unit ID
Network Baud Rate
Halt Delay Minimum
Auto-Request Order Footage
Use Scrap Codes
Manual Shear Scrap Length
Enforce Eclipse Coil Validation
PLC Unit ID
PLC Baud Rate
PLC Parity
Configuration Register Address
Language Select
Numeric Display Format
Auto-Delete Done Orders After
Set Done Items to Ready
Enable Virtual Keyboard
Velocity Display Unit ID
Show User Data – Program Screen
Show User Data – Status Screen
Show Help Preview – Setup Screen
Select Bundle Tag Printer

Bundle Tag Copies
Bundle Tag on Coil Change
135

Length of Label
Select Part Printer
Printer Output Dwell
Printer Output Reaction
Stop To Print
Slow Speed For Print
Tolerance Test For Print
Length of Label
Encoder Enable
Print Speed
Encoder Pulses Per Meter
Print Height
Ink Type
Print Direction
Printer 2 Direction
Print Delay (mm)
Printer 2 Delay (mm)
Column Spacing (mm)
Dot Size (mm)
Double
Overlap
Auto Flush Ink
Auto Flush Time
Edge Offset
Backfeed
Print Speed
Slew Speed
Print Bold
Printer Model
Message Select Length
Print Trigger Source
136

Use PM5400 Commands

Print Mode
Gag Setup Time
Global Material Width Offset

Global Material Gauge Offset
Tool Data Sheet

Tool Data
ID Press Gag X-Offset Y-Offset Axis Name
137

138

Patterns Sheet
Pattern #: __________
Tool Reference Offset Y-Reference Y-Offset

ID
139

Pattern #: __________
Tool ID Reference Offset Y-Reference Y-Offset
140

141

Index
Machine Layout, 64
Manual Punch, 39
A Manual Shear, 38
Advanced Setup, 71 Menu
Analog Output #1, 43 Machine Parameters, 46
Analog Output #2, 43
Asynchronous Print Detect, 40
AXIS, 92
N
NAME, 93
Nested Tooling, 93
C Network Settings, 78
Calibrate Trim, 121
Clock / Calendar, 77
Comm. Port “A”, 44
O
Comm. Port “B”, 44 Offset Distance (Tool Data), 92
Comm. Port “C”, 44 Outputs, 41
Comm. Port “D”, 44
Communications, 78
Correction Factor, 121 P
Pattern, 89
D Press, 89
Press Number, 92
Defining a Tool, 91 Proportional Analog, 43
Die Boost, 42, 109 Punch Complete, 39
DIE BOOST REACTION, 110
Die Set, 89
Q
F Quickset Data, 86
Fast/Slow, 41
R
G REACTION, 111
RS422 High Speed Port, 44
Gag, 89 RS485 Auxiliary Port, 44
Gag Number, 92 RS485 Eclipse Port, 44
General Parameters, 46 Run, 37, 41
H S
Hole Detect, 40 Setup, 45
Setup Menu, 45
Shear Complete, 38, 40
I Shear Dwell Up, 47
Inputs, 37 Shear Up, 42
Shear/Press, 41
Sheet Detect, 39
J Specifications, 125
Speed Logic Analog, 43
Jog Forward, 37
Stopping Modes, 116
Jog Reverse, 37
Stopping Reaction, 116
M T
Machine Data, 46
Tool, 89
143

Tooling Terms, 89
Y
Y-Offset, 92
X
XL200 Cutout Dimensions, 127
Z
Zero Reference Point, 90
144

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XL200 Series Open Loop Controller

Installation Guide &

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Copyright © 2007 − AMS Controls, Inc. All rights reserved.

The most current version of this manual is available at: www.amscontrols.com/files/manuals

AMS Controls, Inc.

314.344.3144 – 1-800-334-5213 (US & Canada) – fax: 314.344.9996 – [email protected]

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Asynchronous Print Detect ....................................................................................................38

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TEST INPUTS AND OUTPUTS ....................................................................................................100

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Chapter 1: Installation Overview

When installing an XL 200OL controller, you must have certain specific

The following steps offer a high-level “bird’s-eye” view of the installation

a Warning: It is essential that the controller be configured and installed

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Chapter 2: System Type

There are two basic categories of roll forming machines:

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• Open Loop Flying Cutoff with Flying Punch Press

Open Loop Flying Cutoff with Flying Punch Press

AMS Controls XL 200 Series

Inc. Qty Home End . 4 5 6 Program

Move Page CE 0 1 2 3 Enter

Figure 1: Roll-former with Flying Cutoff & Punch Press

7. Material is loaded through the entire machine.

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Open Loop Feed-to-Stop, Shear-Only

FEED SYSTEM CUTOFF

Figure 2: Feed-to-Stop Machine with Cutoff

1. Material is fed to the cutoff press.

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Chapter 3: Model Customization

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Model Types and Options

Model Switch I/O

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Model Option Description

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Model Option Description

Combining Model Options

Several model options may be combined together as long as their functionality

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Configuration Switch Settings

Model Types: XL200 & XL200H

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Model Types: XL202, XL206, XL212, XL202H, XL206H, &

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- The Shear Boost functionality can not be enabled for a feed-to-stop

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Model Type: XL266

Switch #1 Switch #2 Switch #3 Total Number of Presses

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Model Types: XL200 & XL200H

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24 Hole Detect Reserved

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Note: Power supplies must not be shared—otherwise, there can be no optical