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hardware installation and testing

Created by hww3. Last updated by hww3, 4 years ago. Version #9.

Additional supporting material and photos are available from the following website:


These instructions describe interfaces that include an electro-magnetic cycle sensor. Current interfaces include a newer optical cycle sensor. For installations using this newer style of sensor, skip steps 14 through 18 and in their place, refer to the procedure in the following document:

optical cycle sensor installation

When you are finished using the caster control interface, it is best to unplug the power adapter. This will ensure that any valves are de-energized. Similarly, do not leave the interface in the "all signals on" state longer than necessary. The "all signals on" state typically occurs when the interface board is first connected to power. The caster control application shuts off all signals when starting.

Getting Started

Items included in interface kit:

Tools and supplies you will need Installation Procedure

This installation procedure should only be performed on a caster with the pot cold and when the motor is not running.

Normally, this procedure will take from 10 to 15 minutes, however the following initial installation instructions include a number of extra steps that will verify that all components of the interface are working and are properly adjusted.

Please carefully read through the following procedure completely before beginning the installation process.

  1. Carefully remove all items from packing and ensure that no damage has occurred during shipment.
2. Make sure that the threaded ring on each pneumatic valve has not become loose during shipment. 3. Hang the interface assembly using hanger strap and screws, making sure that the air bar adapter reaches the air tower on the caster. 4. Attach the interface board using the black wire tie attached to the pipe connecting the two sets of pneumatic valves. 5. Connect your compressed air supply to the interface assembly (20-30 PSI) and verify that there are no leaks. Tighten any loose connectors or valves.
Do not completely loosen the threaded ring, as the valve will separate and the very small components inside will fall out!

6. Remove the second and second from last air fittings (marked with yellow and black paint) from the air bar adapter. Gently insert the air bar adaptor installation pins through the holes until they extend past the gasket approximately 1/2 inch (10 mm).

7. Lift the air bar clamp and disable the paper feed.

8. Place the air bar adapter on the caster.

9. Gently insert the air bar adapter clamps on either side of the air bar adapter. 10. Bring the air bar adapter clamps into place and tighten. 11. Gently remove the installation pins from the air bar adapter. 12. Reinstall the 2 fittings you removed during step 5. 13. Test the pneumatic valves and air bar adapter connection. 14. Attach the cycle detector magnet to the air bar clamp activating rod. 15. Attach the cycle detector sensor to the air tower. 16. Adjust the cycle detector sensor gap. 17. Attach the cycle sensor cable to the interface board. 18. Verify that the sensor is correctly installed 19. Using the Caster control application, test the functionality of each "pin". 20. Using the Caster control application, load and run the test ribbon. 21. Congratulations, you've successfully installed the Monotype control interface.

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