The setup, PCode Change Stops Queue, was disabled for controllers that did not maintain the queue when halting. This setting has other side effects that make it useful to be enabled on these controllers. For example, this setting can also disable the PCode comparison for the Coil Endpoint feature.

It will now be enabled all the time. However, it will still not be visible if the MODBUS interface is controlling it.

Many times, the Item Complete output and its timer are used to run the last pieces of an item out through a roll former. One customer wants a feature that triggers every time the line halts to trigger any cut pieces to be run out through the roll former. One issue is there may be uncut material in the roll former that could strip material out through the shear and into the roll former.

In the past we have solved this sort of issue with the combination of the Uncut Length output and PLC logic. Not all controllers have the output available or access to a PLC.

To solve the customer’s request, we have added the "Item Complete on Halt" setting. It has five options, No, Always and Uncut Length, Halted Only and Uncut Length Only.

When set to No, the Item Complete output works as it always has. It is triggered on the last part of an item.

When set to Always, it will trigger on the standard Item Complete conditions after item completion, and it will be triggered every time the line is Halted from the run mode, provided a part has been produced while running.

When set to Uncut Length, it will trigger on the standard Item Complete conditions after item completion, and it will be triggered every time the line is halted, provided a part has been produced while running and the leading edge of the uncut material is less than the Uncut Length Threshold setting.

When set to Halted Only, it will only be triggered every time the line is Halted from the run mode, provided a part has been produced while running.

When set to Uncut Length Only, it will be only be triggered every time the line is halted, provided a part has been produced while running and the leading edge of the uncut material is less than the Uncut Length Threshold setting.

When Halting, if the Item Complete is active and the either of the Uncut Length options are active and in violation, the active Item Complete trigger will be terminated early to prevent uncut material from being stripped through the shear.

Some additional changes were made so that the Uncut Length Threshold setting is visible even when there is no Uncut Length output available.

The Following improvments have been made to the Dump Hole feauture provided through Flashwizard.

1. The Hole Queue Detector number and its Postion with respect to the shear location is displayed.
2. There is a master Hole Detect Enabled status and an individual Detector Enabled status. The master disables all hole detects.
3. The Current Line Position is displayed.
4. The Last Detected Hole is displayed.
5. All positions are displayed with respect to the Shear Reference Point. Positive values have exited the Reference Point. Negative values are values that have not reached the Reference point.

There was a potential flaw in the Minimum Hole Space test. There is one flag that indicates that a hole has been detected since the Hole Queue has last been cleared. This single flag was adequate, until we added multiple hole detect queues, required for the KMF machine.

On the KMF machine It is possible that a hole detected on one Queue would cause an erroneous Min-Hole Space test on the other queue, preventing it from detecting a valid hole on the second queue.

Each hole queue now has its own flag so that the first hole on an empty queue will always be valid.

We have typically steered away from detecting the traing edge of a hole when hole detecting. Due to possible material burs, oil and other things causing the hole detect input to bounce on the leading edge, we would detect the leading eadge instead.

We have added some additional validation to prevent that from happening. A new setting called Minimum Hole Size has been added. We have also added a setup to select which edge of the hole we are detecting. It has two settings, Leading Edge and Trailing Edge.

Whe we are trying to detect the Trailing Edge of the Hole, the Sensor input must be ON for at least the Minimum Hole Size before we will count a hole on the ON to Off transtion of the sensor. This prevents a minor blip in the sensor state from triggering a hole on the leading edge transiton of a hole.

It is assumed that the Minimum Hole Spacing setup will be larger than the Minimum Hole Size setup.