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Technical Support
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- A Case for Computer Integrated Manufacturing (CIM)
- Basic Methods of Length Control
- Benefits of Computer Integrated Manufacturing (CIM) - Deutsch
- Coil Handling
- Continuous Improvement - Tube & Pipe Journal
- Continuous Improvement in Roll Forming
- Encoder Tracking and Mounting
- Improving Roll Forming Operations
- Part Marking
- Roll Forming and Industry 4.0
- Roll Forming: The Four Basic Machine Types
- Servo Control for Improving Roll Formed Production
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XL200 Series Support
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- Battery Replacement
- Calibrating the Touchscreen of an XL200 Controller
- Extending XL200 Controls with PLC Integration
- Solving Memory Loss and Computer Lockup Problems
- Using Product Codes for Machine Positioning in the XL200 Series Controller
- Using Setup Configurations in the XL200 Series Controller
- Using Tool Configurations in the XL200 Series Controller
- XL200 Direct Ethernet Communication with Eclipse Classic
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- Bar Code Scanners
- Bar Code Scanners for Data Entry
- Boosted Dies
- Calculating Press Reaction
- Checking Press Consistency with Oscilloscopes
- DIP Switch Configuration
- Punch Programming on the XL200
- Sending Saved Parameters or Tool Libraries from Eclipse Classic to XL Controller
- Understanding the XL200 Part Queue
- Using Product Codes for Machine Positioning in the XL200 Series Controller
- Using Setup Configurations in the XL200 Series Controller
- Using the Stitching Feature
- Using Tool Configurations in the XL200 Series Controller
- XL200 Error Codes
- XL200 Parameters
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- BOSS Shear
- Brake & Hump - XL200CLU
- Calculating Press Reaction
- Checking Press Consistency with Oscilloscopes
- Closed Loop Flying Die / Die Accelerator
- Closed Loop Stopping
- Coil End Point
- Extending XL200 Controls with PLC Integration
- Open Loop Flying Die
- Open Loop Stopping / Feed-to-Stop
- Tailout Sensor
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Eclipse Support
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- A Case for Computer Integrated Manufacturing (CIM)
- Benefits of Computer Integrated Manufacturing (CIM) - Deutsch
- Coil Inventory Management with CIM
- Improving Production Capacity with Computer Integrated Manufacturing (CIM)
- Mistakes Happen! CIM for Mistake Prevention in Roll Forming
- Roll Forming and Industry 4.0
- The Quality Gap
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- Automatically Starting Eclipse Classic
- Cable Specifications for RS Communication
- Coil Validation
- Creating an Eclipse Classic Package File
- Deleting Done Orders in Eclipse Classic
- Eclipse Classic Hardware Requirements
- Eclipse Classic Permissions - XLSecurity.exe
- Eclipse Connections
- Eclipse Data Exchange Options
- Establishing Communication with Eclipse
- Implementing Scrap, Delay, and Employee Codes in Eclipse Classic
- Interfacing Eclipse to External Data Systems - Importing and Exporting
- Material Code Query
- Missing Snapshot or Dates for Reports in Eclipse Classic
- Order Downloading Options in Eclipse Classic
- Performing Eclipse Classic Automatic Backups
- Performing Eclipse Classic Manual Backups
- Preventative Maintenance Made Easy
- Replacing a Controller / Recovery from a Memory Clear
- Reporting from Archived Data
- Reporting from Archived Data
- Requesting Eclipse Classic Support
- Sending Saved Parameters or Tool Libraries from Eclipse Classic to XL Controller
- Using a Proxy Server
- VLINX ESR901 Converter Installation and Configuration
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Pathfinder Support
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- Calibrating the Backgauge - Pathfinder v2
- Calibrating the Machine - Pathfinder v2
- Calibrating the Touchscreen - Pathfinder v2
- Cleaning Controller Screens
- Extracting the Pathfinder SDF from a 5XXX/6XXX Machine
- Installing TeamViewer
- Pathfinder PC Backup/Restore/Import Procedure - Pathfinder v2
- Pathfinder PC BIOS Configuration - 5X00
- Pathfinder PC BIOS Configuration - 6X00
- Solving Memory Loss and Computer Lockup Problems
- XL250BB Backup/Restore Function
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- FoldGuard Alignment Guide
- FoldGuard Alignment Guide - LZS-2-FG
- FoldGuard Brochure
- FoldGuard Encoder Installation Manual 1-02
- FoldGuard Frequently Asked Questions (FAQ)
- FoldGuard Operation Manual
- FoldGuard System Installation Manual 1-06
- FoldGuard System Installation Manual 1-07
- Laser Distortion Causes and Solutions Manual 1-02
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MP Series Support
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- MP300 Series Controller Manual
- MP300CL Series Controller Manual
- MP325 Manual
- MP328 Gripper Manual
- MP328CL Gripper Manual
- MP338 Backgauge Manual
- MP338DH Dual Backgauge Manual
- MP342 Manual
- MP343 Manual
- MP350PFD Manual
- MP450S Installation Guide
- MP465 Installation Guide
- MP465 Operator Manual
- MP465N Operator Manual NTM
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Pathfinder Edge Support
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- Accessing Pathfinder Edge
- Installing TeamViewer
- Logging into Pathfinder Edge
- Pathfinder Edge - Profile Object Format
- Pathfinder Edge Published API
- Print an Approval or Production Sheet - Edge
- Understanding Settings - Edge
- Using Categories and Subcategories - Edge
- Using the Profile Editor - Edge
- Using the Profile Library - Edge
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Eclipse Pro Support
- Alert: Eclipse-COMM may be offline
- Alert: Material code XXXXXXXX does not correspond to a known material
- Checking the Status of Eclipse Pro Services
- Connect to Eclipse Pro from a Network Connected Device
- Eclipse Pro Hardware Requirements
- Eclipse Pro Release Notes
- Eclipse Pro Scheduler
- Eclipse Pro Wallboard Andon App Setup
- Error: "Duplicate material codes. MATERIAL =..."
- Machine Performance Standards
- Requesting Eclipse Pro Support
- Schedule Sync Table Definition
- Updating Eclipse Pro
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Accessories Support
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- 4805-XX and 3805-XX Encoder Cable Comparison
- BRKT-2 Assembly STEP File
- Encoder 10-Turn Test
- Encoder Bracket BRKT-1 Dimensional Drawing
- Encoder Bracket BRKT-2 Dimensional Drawing
- Encoder Brochure
- Encoder Sell Sheet
- Encoder Splitter 6390 Electrical Block Diagram
- Encoder Splitter 6390 Sell Sheet
- Encoder Splitter 6390 Shell STEP File
- Encoder Splitter Module 6390 Guide
- Encoder STEP File
- Encoder Tracking and Mounting
- Encoder Wheel KMW Dimensional Drawing
- Encoder Wheel PMW Dimensional Drawing
- KMW-12 Knurled Encoder Wheel STEP File
- NXXXX Encoder Assembly STEP File
- Scrap Reduction Using Two Encoders
- Troubleshooting Encoder Alignment
- Show all articles ( 4 ) Collapse Articles
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Legacy Product Support
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- About the MP401
- Cleaning Controller Screens
- CMP1000 Reference Manual
- CMP11-10 Reference Manual
- CMP12 Reference Manual
- MP100 Reference Manual
- MP101 Reference Manual
- MP101 v2 Reference Manual
- MP103 Reference Manual
- MP103 v3 Reference Manual
- MP237 Reference Manual
- MP257 Reference Manual
- MP37 Reference Manual
- MP38 Reference Manual
- MP39 Reference Manual
- MP401 User Manual
- MP43 Reference Manual
- MP44 Reference Manual
- MP450 Installation Guide
- MP450 Operator Manual
- MP450S Installation and Technical Reference Manual
- MP450S Installation Guide
- MP450S Operator Manual
- MP450Z Operator Manual
- MP46 Reference Manual
- MP465N Operator Manual NTM
- MP54 Reference Manual
- MP55 Reference Manual
- MP550 Operator Manual
- MP56 Reference Manual
- MP57 Reference Manual
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A boost is a hydraulic or pneumatic cylinder used to “shove” a punch or cut tool up to material speed on a roll forming machine. This method of die acceleration is crude and less precise than servo actuation, but it’s cheap and effective. Typically, a boost is only used when the material is not strong enough to support the weight of the die. In this case, the boost helps by pushing the die out as the press is firing so the tooling is already in motion by the time it hits the material.
Boosts are not really used for accuracy, and the boost should not play a role in determining calibration or accuracy on the machine. When establishing press reaction times, the boost should be completely disabled if at all possible. Once the press reaction times and calibration are established, then the boost should be reconnected and it’s timing established. The function of the boost is to prevent material deformation due to the forces involved when trying to use the material to accelerate the weight of the die.
In AMS controllers, the boost output and the press output have a special relationship based on the series of controller (MP300, XL100, XL200). It’s important to understand this relationship to get the best results from the equipment. There are four parameters that work together to determine the timing states of the two outputs; Press (or Shear) Dwell, Press (or Shear) Reaction, Boost Dwell, and Boost Reaction.
MP300, XL100 Series and XL 200 series (up to v2.06)
The Shear Dwell parameter should be set to a time corresponding to the time required to break through the thickest/strongest material run on the machine. This time is found by trial-and-error, requiring the user to load his thickest material into the shear and perform a standing cut, increasing or decreasing the Shear Dwell parameter until just enough time is programmed to break through the material with a single press fire. For the purpose of this document, it is assumed that a Shear Dwell time of 0.1 s is sufficient to break through the thickest material run, and that the shear/boost combination is installed on a functioning roll forming machine.
With only the Shear Dwell set, the corresponding boost output will turn on at the same time and for the same amount of time as the its press output. A shear/boost combination is programmed only with Shear Dwell time. Both the shear and the boost will turn on for 0.1 s of time.

Press and Boost Fire at the Same Time
Because of the nature of attempting to hit a moving target, it is necessary to compensate for speed changes on the machine. The Shear Reaction parameter handles the time error induced when speed changes occur. While establishing the Shear Reaction time, the boost cylinder should be disabled so that it does not impact the operation of the shear die. This can typically be accomplished by removing the solenoid to the valve that controls the boost. The test for Shear Reaction can then be performed at a speed slow enough that the material will support the weight of the die without the boost. Learn more about Press Reaction calculations.
Once the shear’s reaction time is determined, it is entered into its corresponding parameter. This affects both the shear and the boost. Because the boost output is tied to the shear output, both signals are shifted forward in time by the programmed reaction time. Both outputs will turn on 0.05 s earlier, and off 0.05 s earlier. The original timing states are shown to represent the original starting point.

Shear Reaction Shifts Both Outputs Forward in Time
After entering the parameters above, the boost is reconnected to the die and some sample parts are run. Often at this point, it might be observed that the die is dragging, or “hanging up” on the leading edge of the material. To solve this problem, some amount of Shear Boost Dwell is added to continue pushing the die forward as the tooling retracts out of the material.

Adding Boost Dwell Can Prevent the Die from Hanging
This is the first time that the boost begins to behave differently from the shear. Up to this point, the boost turned on at the same time, and for the same amount of time as the shear. Now, the boost stays one for an extra 0.1 s for a total time of 0.2 s. Even though the shear and boost are fired simultaneously, the boost stays on longer, allowing the shear to retract with no back pressure on the material. However, at higher speeds, the user might notice some buckling on the leading edge of the next piece. This is an indication that the shear die is not fully up to speed by the time the blade contacts the material. To solve this problem, Shear Boost Reaction is added as a way to get the shear die moving earlier, so the die has time to more closely meet line speed by the time the blade contacts material.

Shear Boost Reaction Pre-fires the Boost
Even though the issue of material buckle on the leading edge of the next piece has been solved, shifting the output forward in time has brought the system back to the point where both the boost output and shear output are turning off at the same time. The shear might begin to hang up on the leading edge of the material again, so even more Shear Boost Dwell time could be required for consistent operation.
XL200 Series (v2.10 and later)
Starting with v2.10, it was decided that the XL200 series controller should allow the user completely independent control of the press and boost outputs. This significantly impacts the functionality of the boost output, especially if the user is familiar with the old operation method.
The Shear Dwell parameter functions identically in both the old and new software versions. The time entered must still be found by trial-and-error by performing standing cuts on the thickest material that will be run through the machine.
With only the Shear Dwell set, the corresponding boost output will not turn on. A shear/boost combination is programmed with Shear Dwell time. Only the shear will turn on for 0.1 s of time.

Shear and Boost Outputs are Independent of Each Other
In any mode of operation, the system must account for the reaction time of the press in order to make accurate parts from start to finish and through all speed ranges. While establishing the Shear Reaction time, the boost cylinder should be disabled so that it does not impact the operation of the shear die. This can typically be accomplished by removing the solenoid of the valve that controls the boost. The test for Shear Reaction can then be performed at a speed slow enough that the material will support the weight of the die without the boost. Learn more about Press Reaction calculations.
Once the shear press reaction time is determined, it is entered into its corresponding parameter. This only affects the shear output. The boost output “on” state will be based on the original target coincidence point (where the shear would have originally turned on).

Shear Reaction Only Affects Shear Output
After entering the parameters above, the boost is reconnected to the die and some sample parts are run. Often at this point, it might be observed that the die is dragging, or “hanging up” on the leading edge of the material. To solve this problem, some amount of Shear Boost Dwell is added to continue pushing the die forward as the tooling retracts out of the material.

Shear Boost Dwell Pushes the Die and Keeps it Moving
At this point, the shear is fired 0.05 s before the boost turns on. When the boost is fired, it stays on longer than the shear output, allowing the shear to retract with no back pressure on the material. However, at higher speeds, the user might notice some buckling on the leading edge of the next piece. This is an indication that the shear die is not fully up to speed by the time the shear blade contacts the material. To solve this problem, Shear Boost Reaction is added as a way to get the shear die moving earlier, so the die has time to more closely meet line speed by the time the blade contacts material.

Boost Output is Fired Before Shear Output
After the last parameter change, the boost output fires 0.05 s before the shear output, helping to bring the die up to material speed before the blade contacts the material. Because of the shift in reaction time, it might be necessary to go back and increase the Shear Boost Dwell parameter to force the boost to keep pushing the die as the blade retracts out of the material, if the material starts to hang up on the blade again.