OPERATIONS

MANUAL
BERRIDGE
BATCH CONTROL
COMPUTER

A PROGRAMMABLE CONTROLLER
FOR USE WITH ALL BERRIDGE
PORTABLE ROLL FORMERS

OWNER:
Berridge
Manufacturing
Company
DATE: SER. NO.:
PAGE 2
CONTENTS

I. GENERAL DESCRIPTION ............................................................................................ 4

II. EQUIPMENT NOMENCLATURE, FEATURES & SPECIFICATIONS ......................... 5

III. INSTALLING THE BATCH CONTROL COMPUTER & CLUTCH/BRAKE ................ 6-8

IV. CALIBRATION, PROGRAMMING & OPERATION ..................................................... 9-10

V. MAINTENANCE ........................................................................................................... 11

VI. SAFETY ....................................................................................................................... 11

VII. PARTS LIST ............................................................................................................... 12

VIII. RETURN FORM ........................................................................................................ 13

PAGE 3
I. GENERAL DESCRIPTION

T
he Berridge Portable Roll
Former Batch Control Com
puter is available as an
option for all models of both newly-
purchased and long-term leased
roll formers, or as a retrofit kit for
all existing Berridge Portable roll
Formers.
The Batch Control Com-
puter Retrofit Kit consists of the
Applied Microsystems AMS Model
MP450B Computer Control with
Encoder and Clutch Brake which
provides precision control of the
roll former electric motor for exact
lengths. A standard Berridge Por-
table Roll Former Mounting
Bracket and bolts is also included
in the kit. Instructions for mount-
ing the control computer and con-
necting to the power supply and
motor are included in this operations manual. The large, easy-to-read LCD display panel
This precision control computer, which is cus- shows programmed quantity, programmed length,
tom designed for Berridge Portable Roll Formers with quantity of the current length remaining to be formed,
their hand-operated entry shear virtually eliminates and the length of material which has moved past the
scrap waste when changing panel lengths and saves cutoff.
valuable man hours on the job site. The heavy-duty case is also moisture resis-
This manual also contains detailed instruc- tant and includes an internal heater for cold tempera-
tions for converting the operation of the computer ture operation.
from the factory default of metric to feet and inches.

PAGE 4
II. EQUIPMENT NOMENCLATURE
BERRIDGE BATCH CONTROL COMPUTER

1. LCD DISPLAY PANEL

$ 2. MEMBRANE KEYPAD
$  3. "SHEAR" LIGHT/BUTTON
!  4. "RUN" BUTTON
% 5. "STOP" BUTTON
6. FRONT PANEL COVER
" SCREWS
7. MODEL NO./SER. NO. PLATE
8. ON/OFF POWER SWITCH
9. POWER CABLES
# 10. MOUNTING BRACKET

$ $

& '
'

FEATURES BATCH CONTROL COMPUTER SPECIFICATIONS

ï Operates in feet & inches or metric POWER REQUIREMENTS

ï Accurate to +/- 1/16" AC DC
ï Custom designed for portable, pre-cut Input Voltage 115 VAC 12 VDC
rollformers with hand-operated shear. Input Current 1 Amp. .5 Amp
ï Easy to operate and program. + output load + output load
ï No scrap between length change overs. OUTPUTS
ï Current order status display shows: Rollformer Rollformer Forward 12 VDC Relay
-- programmed quantity. Clutch/Brake 1 N.O. .5 Amp max. current
-- programmed length. INPUTS
-- quantity left to make. None
CONTROL SWITCHES
-- material past the cutoff.
CONTROL SWITCHES
ï Simple Automatic Calibration procedure to Run Momentary Push Button
fine tune lengths. Halt Momentary Push Button
ï Moisture resistent enclosure. Shear Ready/Complete Illum. Momentary Push Button
ï Internal heater for cold temparature operation
ENCODER INPUT
Type Quadrature with Complements
Voltage 5 VDC
Max. Encoder Load 200 mA
Max. Pulse Rate 10,000 pulses/second
OPERATION
OPERATION
Max. Nr. of Batches 999
Maxt. Part Length 999 ft. 11.999 inches
Max. Parts/Batch 999
Units of Measurement ft/inch or mm

PAGE 5
III. OPERATING INSTRUCTIONS

MOUNTING THE BATCH CONTROL COMPUTER

ON YOUR BERRIDGE PORTABLE ROLL FORMER: section of wiring diagram (fig. 1).
3. Connect wiring as shown in bottom section of
Depending on the model of Berridge Roll Former which Wiring Diagram (fig. 1).
you own or lease, you will be sent one of two types of 4. Connect one end of the white wire to the white wire
Batch Control Computer installation kits: One kit will be from the new Switch Cover. Run the wire through
for rollformers without clutch/brakes, the other for those conduit from Switch Box to Motor. Connect the
with clutch/brakes. At this writing, only the Zee-Lock other end to L2 inside of Conduit Box on Motor.
(SP21) machines have clutch/brakes. This manual in- 5. Screw new Switch Cover onto Switch Box. The
cludes instructions for wiring and mechanical installa- wiring portion of the installation is now complete.
tion of both types of kits. 6. Remove the Shear Feed-in-Guide from the operator
side of the roll former.

fig. 1: WIRING DIAGRAM FOR INSTALLATION OF BERRIDGE BATCH CONTROL COMPUTER ON ROLLFORMERS WITH CLUTCH BRAKE

7. Install the new Feed-in-Guide using the bolts re-

INSTALLING THE BERRIDGE BATCH CONTROL moved in step 6. The wheel on the encoder should
COMPUTER ON ROLLFORMERS WITH CLUTCH/ be on top, the connection on bottom. (When mate-
BRAKE: rial is fed into the machine, make sure the wheel on
the encoder is making firm contact with the metal.
LIST OF COMPONENTS: If it is not, the mounting bracket may need to be bent
inward slightly. Also, the backer wheel on the back
- Computer Control Unit side of the shear may need to be moved toward the
- Cover for Switch Box encoder by shimming with flat washers.
- Shear feed-in guide with Encoder attached.
- Angle Bracket for mounting Batch Control Computer INSTALLING THE BERRIDGE BATCH CONTROL
- Single white wire COMPUTER ON ROLLFORMERS WITHOUT
CLUTCH/BRAKE:
INSTALLATION INSTRUCTIONS:
LIST OF COMPONENTS:
1. Remove cover from Switch Box mounted above - Computer Control Unit
shear on rollformer. - Warner Clutch/Brake pre-wired with Palm Switch
2. Remove jumper from Palm Switch as shown in top Box

PAGE 6
III. INSTALLING THE BATCH CONTROL COMPUTER & CLUTCH/BRAKE

- Shear feed-in guide with Encoder attached. lead from the Clutch/Brake into the hole in the Junction
- Angle Bracket for mounting Batch Control Computer Box.
3. Connect the two wires from the Clutch/Brake in the
INSTALLATION OF CLUTCH/BRAKE UNIT following manner: black to black from power cord and

FIG. 2: INSTALLATION SCHEMATIC FOR BERRIDGE BATCH CONTROL COMPUTER UNIT (ROLLFORMERS WITHOUT CLUTCH/BRAKE)

white to white from power cord.

Mechanical Installation:
INSTALLATION OF PALM SWITCH:
1. Unbolt the motor from the Gear Box housing. Note the
position of the Lovejoy coupling on the motor shaft 1. Hook the bracket attached to the Palm Switch over the
and remove. top plate of the rollformer in the space where the shear
2. Place the Lovejoy coupling at the same position on is located.
the output shaft of the Clutch/Brake. 2. Tighten the set screws in the top of the bracket.
3. Remove the key on the motor shaft and place the Tighten only enough to hold the bracket in place -
Clutch/Brake onto the motor. Use a 1/8" Allen wrench DO NOT OVERTIGHTEN.
to help align the output shaft of the Motor and the input
sleeve of the clutch/brake. Bolt the Clutch/Brake to INSTALLATION OF BATCH CONTROL COMPUTER
the motor using the four bolts provided and then UNIT:
tighten the two Allen set screws to the Motor shaft. The Berridge Batch Control Computer is to be mounted
4. Bolt the Clutch/Brake and Motor Assembly to the to the left of the shear on the operator side of the
Gear Box housing. rollformer. Mount as follows:

Electrical Installation: 1. On the operator side of the rollformer to the left of the
1. Note the Junction Box on the electric Motor where the manual shear, there are two gold vertical framing
electrical conduit is fastened. A 7/8" diameter hole members, one immediately after the shear and an-
must be drilled into this box on the side that faces the other down toward the exit end of the machine. These
Clutch/Brake. uprights are attached to the top plate with two bolts.
2. After the hole from step 1 is drilled, attach the conduit

PAGE 7
III. INSTALLATION (CONTINUED)

Remove the top bolts from these two uprights.

2. Place the angle bracket on the machine with the bolt
holes aligned and replace the bolts removed in step 1.
3. Attach the Batch Control Computer using the bolts in
the Angle Bracket.
4. Attach the leads from the Batch Control Computer to
the Encoder and the Switch Box.

INSIDE THE CONTROLLER
CAUTION: NEVER REMOVE THE COVER OF THE BERRIDGE
BATCH CONTROL COMPUTER WITH POWER APPLIED.
POWER MUST BE REMOVED FROM THE SOURCE BEFORE
THE COVER MAY BE REMOVED. SIMPLY TURNING OFF THE
POWER SWITCH OF THE CONTROLLER IS NOT GOOD
ENOUGH.

There are two functions you may need to perform which

require you to take the cover off the controller and look FIG. 3: BATCH CONTROL COMPUTER PC CIRCUIT BOARD
inside. These functions are:
1. ENGLISH/METRIC TOGGLE SWITCH
2. ENCODER CONNECTOR PLUGS
1. Changing the counting direction of the controller from
clockwise to counter clockwise (inverting the counter
wheel assembly will necessitate this modification). 2. Changing the Display from English to Metric
Note: Because of the manner in which Berridge
instructs the controller to be mounted on the pro- The Berridge Batch Control Computer can be con-
vided bracket, the controller/encoder will only oper- figured to read in English units (feet and inches) or
ate in the clockwise (positive measurement) direc- Metric units (millimeters). This parameter can be
tion, thus it will not be necessary to change the modified by changing the position of the toggle switch
counting direction unless the mounting bracket and on the right hand side of the computer circuit board.
procedure is modified). Please note that changing the position of this switch
will erase all of the calibration data and job data which
2. Changing the Display from English (feet & inches) to is stored in the computer's memory.
Metric.
Technical Support:
The photograph in figure 3 shows you the Berridge If you need assistance with the installation of the
Batch Control Computer circuit board and the location of Berridge Batch Control Computer unit, call Ber-
the two adjustments previously described. These ad- ridge Manufacturing Company Rollformer Opera-
justments should only need to be made once. tions in Seguin, Texas at (210)-303-3107 or (800)303-
0811. Be prepared to give the model number and
ADJUSTMENTS INSIDE THE BATCH CONTROL serial number of your rollformer.
COMPUTER:
1. Changing the Counting Direction of the Computer: YOU ARE NOW READY TO BEGIN PRODUCTION WITH THE
The encoder cable attaches to the circuit board on BERRIDGE BATCH CONTROL COMPUTER SYSTEM.
the connector located in the lower left-hand corner.
The cable is made with two separate connectors,
one for clockwise (CW) encoder rotation and one for
counter-clockwise (CCW) rotation. If the encoder
counts negative when coil is moving in the forward
direct, swap the encoder connector on the back of
the computer circuit board. (See above note)

PAGE 8
IV. CALIBRATION, PROGRAMMING & OPERATION

INITIAL TESTS CALIBRATION

After the wiring has been completed, you are ready to Once the Berridge Batch Control Computer has
apply power to the controller. Turn on the power switch been tested and the initial adjustments have been made,
and watch the display. It will look like this: you are ready to run some panels on your Berridge
Portable Roll Former.
MP450B Ver. 1.00 Make sure the Batch Control Computer is mounted
properly. The counter wheel must be parallel to the
© 1991 by AMS direction of material flow and must be at a right angle to
the coil material, with NO SLIPPAGE between the wheel
After a few second, the display will change to: and the material.
Calibration is a process whereby the Batch Control
Computer corrects itself for inaccuracies in the size of
0 0 0' 0.00" the measuring wheel. We assume the wheel is exactly
0 0' 0.00" 12" in circumference when in actuality this is not the
case. When a calibration is performed, an internal cor-
Attach the encoder to the encoder cable and turn the rection factor is calculated so that the part length you
counter wheel by hand. Be sure to turn the wheel in the program is the actual part length produced by the Batch
direction that the material will cause it to turn when it Control Computer.
moves in the forward direction. Watch the display to Calibrate the computer by pressing the CAL key and
verify that the length is counting in the positive direction. following the direction on the readout. The Berridge
With the controller in the HALT mode, the roll former Batch Control Computer need only be calibrated once.
may be jogged with the external JOG push button. Test
the operation of the JOG circuit.

FIG. 5: PRESS THE "PRG" KEY TO ENTER THE PROGRAM MODE.

PROGRAMMING
When programming the Berridge Batch Control Com-
FIG. 4: PRESS THE "RUN" BUTTON TO VERIFY THE OPERATION OF THE puter, there are three pieces of information required --
COMPUTER AND TO BEGIN PRODUCING PANELS. the BATCH (or job) NUMBER, the QUANTITY of pieces
The Berridge Batch Control Computer enters the needed, and the LENGTH of the pieces. Follow these
RUN mode by pressing the RUN (figure 4) push button steps to program the computer:
on the computer's front panel. Verify the operation of the
RUN and HALT push buttons. 1. Press the PRG key (Fig. 5) to enter the program mode.
Once the proper operation of all of the control switches
has been verified the machine may be loaded with coil 2. Enter the BATCH Number that you want to program.
and the controller may be calibrated. Press the ENT key to accept this information.

PAGE 9
IV. OPERATION (CONTINUED)

3. Enter the QUANTITY of pieces in this batch. Press the rollformer.

ENT key.
1. To load a coil, place the coil on the uncoiler table, feed
4. Enter the LENGTH in feet and press the ENT key, then the coil into the slot in the lexan housing and jog the
enter the inches and press the ENT key. leading edge of the coil past the shear as would normally
be done in manual operation.
5. The computer will ask if you would like to halt (pause)
after this BATCH (Job Number XX). Press any number 2. Shear off the leading edge of the coil.
key (0-9) to toggle the response from NO to YES. If NO
is selected, the Batch Control Computer will begin with- 3. When programming is complete and you are ready to
out hesitation to produce parts from the next sequential commence production, press the SHEAR Button on the
BATCH (Job Number) when the first BATCH is com- front panel of the Batch Control Computer. (Notice that
pleted. Enter as many BATCHES (jobs) as you wish, his causes the length reading on the bottom line of the
then press the PRG key when your programming is LED Display to zero out -- If the bottom row of numbers
complete. is NOT zeroed out immediately after programming and
before you run your first panel, press the SHEAR button
The * key returns you to the Main Status Display. The top to zero out the LED display, then press the RUN button)
row shows the current Job Number, the Quantity pro-
grammed for this job, and the programmed Part Length. 4. Press the RUN Button (fig. 7) to begin running the first
The bottom row shows the Quantity remaining to be panel.
made for this job and current length of material which is
out past the shear. 5. When the material reaches the programmed length,
the rollformer will automatically stop and the SHEAR
If you make a mistake during the programming process, Button will light up.
press the CE key to clear the entry and enter the correct
information. When programming has been completed 6. Shear the material and press the SHEAR Button to
and the computer has returned to the main display, there begin running the next panel in the batch.
will be two rows of numbers visible (fig. 6)
Fig. 6 The RUN Button needs to be pressed only when starting
Batch No. Pcs Length the first panel or to restart the machine when the red
HALT Button has been pressed. The Batch Control
Computer will continue to run panels until the pro-
10 155 45' 6.25" grammed quantity is reached or until the HALT button is
pressed.
154 40' 0.00"
After an automatic halt, the computer may be restarted
by pressing the RUN button, provided there are more
Quan. Remaining Length past shear jobs stilled programmed to run.

Jobs may be programmed "on the fly", meaning that new

The top row shows the current batch number, the jobs or batches may be programmed into the Batch
quantity in this batch, and the length of the parts. The Control Computer while currently programmed jobs are
bottom row shows the quantity remaining and the length being run, in order to maximize your production and save
of material past the shear. even more manhours.

NORMAL OPERATION To change from one batch to another, press the PRG key
When using the computer, the Drum Switch Lever must to enter the programming mode, then select the batch
be toggled to either forward or reverse. The green Palm that you want by entering the appropriate batch number.
Switch Button functions as a job button when loading a
new coil or running the last part of a coil out of the

PAGE 10
IV. MAINTENANCE INSTRUCTIONS

Although the Berridge Batch Control Computer unit is an enclosed encoder unit which requires no periodic maintenance,
care must be exercised to prevent damage to the unit, either by impact from job site equipment or exposure to the
elements. In order to protect sensitive electronic components inside the housing, the unit must be kept clean and dry.

V. SAFETY

It is important to abide by normal safety rules when operating the Berridge portable roll formers or othe electrical equipment.
While Berridge recommends the following minimum safety practices, the company accepts no responsibility for personal
injury or property damage incurred while operating the machine.

A. Make sure electrical outlet is grounded.

B. Do not operate machine in rain or stand in water while operating .

C. Make sure electrical cord is free of cuts and exposed wire.

D. Keep hands and clothing out of the rolls and the shear blade.

E. Keep wheels locked on the machine except when necessary to physically move it.

F. Do not stand under coil when loading or unloading machine.

G. Do not operate machine with plexiglass panels removed.

PAGE 11
 VI. BATCH CONTROL COMPUTER
PARTS LIST

FOR ROLLFORMERS WITH CLUTCH/BRAKE AL-

READY INSTALLED:

ï Batch Control Computer Unit

ï Cover for Switch Box
ï Shear Feed-In Guide w/Encoder Attached
ï Angle Bracket for mounting Batch Control Computer
unit
ï Single White Wire.

FOR ROLLFORMERS WITHOUT CLUTCH/BRAKE:

ï Batch Control Computer Unit

ï Angle Bracket for Mounting Computer Unit
ï Shear Feed-In Guide w/Encoder Attached
ï Clutch/Brake, pre-wired w/Palm Switch Box

PAGE 12
 BATCH CONTROL COMPUTER
RETURN INFORMATION

If it should become necessar to return your Berridge Batch Control Computer for any
reason, please use this form to supply the information required to properly
identify your unit and resolve the problem.

DATE RETURNED ___________________________________________________________

MODEL # ___________________________________________________________________

SERIAL # ___________________________________________________________________

DESCRIPTION OF PROBLEM: _________________________________________________

___________________________________________________________________________

___________________________________________________________________________

___________________________________________________________________________

FILL OUT & MAIL OR FAX TO:

BERRIDGE MANUFACTURING COMPANY

ROLL FORMER OPERATIONS
2201 Rudeloff Road
Seguin, TX 78155
Fax: 210-303-0530

THIS PORTION TO BE COMPLETED BY

BERRIDGE ROLL FORMER OPERATIONS:

REPAIRS: ___________________________________________________________________

___________________________________________________________________________

LABOR COST: _______________________________________________________________

___________________________________________________________________________

PARTS COST: _______________________________________________________________

___________________________________________________________________________

PAGE 13
PAGE 14
PAGE 15
 BERRIDGE MANUFACTURING COMPANY
1720 Maury Street, Houston, Texas 77026
(800) 231-8127
Fax: (713) 236-9422
www.berridge.com

for Roll Former Technical Assistance

Call Seguin Branch toll-free: 1 (800) 303-0811
Fax: (830)-303-0530
SALES HQ SALES & DISTRIBUTION BRANCH OFFICES
SAN ANTONIO, TX SEGUIN, TX DENVER, CO CHICAGO, IL ATLANTA, GA
6515 Fratt Rd 2201 Rudeloff Rd 7801 E. 40th St. 1175 Carolina Dr. 319 Lee Industrial Blvd
San Antonio,TX 78218 Seguin, TX 78155 Denver, CO 80207 W. Chicago, IL 60185 Austell, GA 30168
1-800-669-0009 1-800-303-0811 1-800-735-3703 1-800-488-7415 1-800-927-9712
Fax: 210-650-0379 Fax: 830-303-0530 Fax: 303-322-3810 Fax: 630-231-7520 Fax: 770-941-7344

REV. Aug 2000

Batch Control Computer Manual - 16pg.pm6