The user can clear most problems, but AMS experts are always ready to help if needed.

We have many years of experience with all types of length controls and coil processing equipment. Our experience shows that problems are grouped into:

• Machine problems (most common)
• Operator mistakes
• Incorrect Setup data
• Corrupted controller memory
• Cable damage
• Controller fault (least common)

Troubleshooting is just a logical series of steps which leads to the likely cause of a problem. The only tool you need are an accurate scale or steel tape, and perhaps a multimeter.

This guide helps the user to help himself. Follow these suggestions in the order listed.

If you are unable to remedy the problem using this guide, printing a copy and answering the questions can help the AMS technician to help you more quickly.

Troubleshooting Guide

When did the Problem Start?

• Did the machine work properly at one time? If not, have you done the Calibration procedure?

• If the machine did work properly at one time, what has changed since then?

• Did the problem start after routine maintenance? After electrical panel work? After a material change? After an operator change? Trace backwards in time to find out what's different.

Check the Machine

• Check the Encoder to make sure it tracks the material perfectly.

• The encoder wheel must be at right angles to the material. The wheel must rotate exactly parallel to the direction of material movement.

• The wheel must be in firm contact with the material. No slippage is allowed!

• Re-run the length Calibration Trim procedure after any changes to the encoder mounting.

• Check the encoder cable connections. They may have worked loose from material movement or vibration. Make sure there are no nicks or cuts in the cable.

• Check the shear (or punch) press to make sure that it returns fully to its home position after each cycle. The press will make accurate cuts only if it starts from a known position for each cycle.

• Re-run the length Calibration Trim procedure after any changes to either press.

• Visually check other parts of the machine for loose fasteners, excessive wear, proper lubrication, proper material feed, and roll former adjustment.

• Re-run the length Calibration Trim procedure after any changes to the machine.

Collect Data

Often the problem is that the machine is making out-of-tolerance parts. To troubleshoot this type of problem, the best method for collecting information is as follows:

1. Run a large (25+) sample of parts, numbering each part as it comes off the machine.
2. Measure the parts in the order they came off.  These measurements should be as accurate as possible and they should be recorded.
3. Fax a copy of the measurements to AMS (314-344-9996) for analysis, including the length you were trying to run, a copy of the current controller setup parameters, and the model and serial number of the controller.

If length and punch placement seem to vary at random, check the encoder mounting very carefully. The encoder must move with the material, and cannot be allowed to slip. If dimensions are off in a consistent pattern, run the Calibration Trim procedure.

Re-check Setups

Re-check setup values with originally recorded values. When you installed the controller, you should have recorded the Setup values on the form provided in the manuals for your machine TYPE. Make sure that none of these values has changed.

Run the Calibration Procedures

When you do the Calibration Trim, take great care to make accurate measurements. Be sure that you know how to reduce measuring error as much as possible with the scale or steel tape you use. A loose tip on your steel tape can add a large error into your measurements.

Use Built-in Diagnostic features

The AMS Controller has a display mode that allows you to monitor the controller's inputs and outputs. Watch this display while the machine is running to check for slowdown, stopping, die accelerator, and press actuation points.

On the main Status display, you can watch line speed and distance passed the shear. Compare what you see here to what should be happening as the machine runs.

Check Incoming Power

Check incoming power for proper voltage. If you suspect fluctuations, watch the indicator on an old-fashioned analog meter to see if they show up.

Fancier line monitors are available for stubborn cases that you can't see on ordinary meters. Use a recording line monitor to find problems that seldom show up. Your local power company may be able to help with this.

Clear Memory

Clearing memory will erase all Setup, Pattern, and Order information in the AMS controllers memory.

Don't try clearing memory unless you have written down all Setup, Pattern, and Order information for re-entry.

Don't try clearing memory unless you have tried everything else above.

You can clear all storage in the controller (including Setup and Order data) by following this sequence:

1. Be sure the Setup Lockout key switch is "off".
2. Turn off power to the controller.
3. Press and hold down the number 5 key on the keypad.
4. Continue holding the 5 key down while you turn power back on to the controller.
5. Continue holding the 5 key down for 5 seconds after turning power back on.  Then take your finger off the 5 key.
6. The controller should power up in the setup screen of the controller.
7. Enter setup and job information and run.