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Mon gb 01 04.04.

2005

Technical Training
EM / EMC
MONITOR

Setup of control unit

Power supply

Description of plug-in boards

List of error messages Service information

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Accompanying material for technical training course

Mon gb 01 04.04.2005

Table of contents
Monitor control unit.................................................................................................................... 3
Arrangement of boards in CU...................................................................................................... 4
Setup of control system and EM / EMC Monitor block diagram...................................................... 5
Control components and their applications................................................................................... 6
Program versions and their use EM Monitor.................................................................................. 7
Program versions and their use EMC Monitor............................................................................... 8
Details about program version V 5.0 ( 1990 Drupa ).................. .................................................... 9
Excerpt from IP 2 / 97 ( Reduction of program versions ) .............................................................. 10
Voltage supply ( Power Module ) ................................................................................................ 11
Control voltages........................................................................................................................ 12
Power Supply ( PS ) plug-in board.............................................................................................. 13
Central Processor ( CP 1 ) plug-in board ................................................................................... 15
Positioning Interface ( PI )......................................................................................................... 15
Positioning Interface ( PI ) plug-in board...................................................................................... 17
Linear measuring system.......................................................................................................... 18
Interchangeable memory and Motor Control Unit ( MCM unit )....................................................... 20
Cutting circuit ( SK ) ................................................................................................................ 21
Cutting circuit ( SK ) plug in board............................................................................................. 22
Cutting circuit ( SK ) with two-channel hydraulic system.............................................................. 23
Light barrier ( LS ) ................................................................................................................... 24
Video Controller ( VID ) and Monitor ( CRT ) ............................................................................... 25
Keyboard Computer ( KC ) and control unit ( BTM )..................................................................... 25
Timer board ( CLK ) and PMS - CARD ...................................................................................... 27
New knife change.................................................................................................................... 27
Circuit diagrams...................................................................................................................... 29
Parts lists............................................................................................................................... 37

Addendum
List of error messages and service information

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Mon gb 01 04.04.2005

Control panel Monitor

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Mon gb 01 04.04.2005

Arrangement of plug-in cards in the CU

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Mon gb 01 04.04.2005

Setup of control unit


The block diagram of the POLAR EMC MONITOR illustrates the structural setup of the control system.
The 16-bit CP 1 (Central Processor) computer board is the heart of the control system. All the other
plug-in cards in the electrical installation facility beneath the machine front table are linked via two
independent bus systems with the CP 1.
The exchange of data with the keyboard computer (KC) on the control panel is performed via serial
interface.

Block diagram of EM / EMC Monitor

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Control components and their use

Title

Application

Machine type

PM
PS
CP 1
PI
VID
CRT
SK
MCM
KC
BTM
BTM
LS
CLK
SDS

Power Module
Standard version
Power Supply
Standard version
Central Processor
Standard version
Positioning Interface
Standard version
Video Controller
Standard version
VDU
Standard version
Cutting circuit
Standard version
Motor Control
Standard version
Keyboard Computer
Standard version
Control panel
Standard version
Control panel
Standard version
Light barrier
Standard version
Clock
Standard version
Automatic star-delta switch
( not on model 92 )
SFM Special function
Autotrim, gripper,
Monitor
Connection to TRB 3BL,
Programmable
outputs (EXT key)
SHM Special hydraulic system
Lifts that can be lowered
Monitor Side gauges,
Backgauge lock
DNF Swivel / tilting backgauge
Swivel backgauge, tilting backgauge
Fixomat
Fixomat
SER Special electr. system
Swivel backgauge, tilting backgauge
Relay plate
Servo Servo control
Optimized
High-speed backgauge
PDR Clamping pressure regulation Automatic
Clamping pressure regulation
PMS Polar - Memory Additional
Systemprogram memory

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EM / EMC
EM / EMC
EM / EMC
EM / EMC
EM / EMC
EM / EMC
EM / EMC
EM / EMC
EM / EMC
EMC
EM
EM / EMC
EMC
EM / EMC
EM / EMC

EM / EMC

EMC
EMC
EMC
EMC
EM / EMC

Accompanying material for technical training course

Mon gb 01 04.04.2005

Program versions and their use


If the CP1 or VID plug-in card needs to be replaced because of a defect, please remember that the card
must be compatible with the machine equipment. Program versions with the addition S can only be used
with the optimized high-speed backgauge optional equipment. ( only on EMC )
Board KC 0185 id. no.: 020111 can only be used with versions V 1.0 - V 4.1.
As of version V 5.0 the board KC V 2.1 with id. no. 023831 has been used.
As of version V 6.0 the board KC V 2.2 with id. no. 023832 has been used.

Table of the existing EM MONITOR program versions and all the


available combinations

CP 1
Video
Monitor
Monitor
Prog. Version Text Version Id. No.
Prog. Version Id. No.
Monochrom Color
V 2.0
T 06 EG
020930
V 3:0 (2.0)
020620
"
V 2.0
T 07 Skand. 020931
V 3.0 (2.0)
020621
"
"
V 3.1
T 08 EG
020932
V 3.0 (2.0)
020620
"
V 3.1
T 09 Skand. 020933
V 3.0 (2.0)
020621
"
"
CP Version no longer available = see IP 2 / 97 =
V 4.0
T 08 EG
023770
V 3.0
020622
"
"
V 4.0
T 09 Skand. 023780
V 3.0
020622
"
"
V 4.1
T 08 EG
023771
V 3.0
020622
"
"
V 4.1
T 09 Skand. 023781
V 3.0
020622
"
"
V 4.2
T 08 EG
023772
V 3.0
020622
"
"
V 4.2
T 09 Skand. 023782
V 3.0
020622
"
"
V 4.3
T 11A EG
023773
V 3.0
020622
"
"
V 4.3
T 11B Skand. 023783
V 3.0
020622
"
"
V 4.4
T 12a
023774
V 3.0
020662
"
"
V 4.4
T 12b
023784
V 3.0
020662
"
"
As of V 5.0 with PMS Card and KC v 2.1
V 5.0
T 08 EG
024350
V 3.0
020622
"
"
V 5.1
T 08 EG
024351
V 3.0
020622
"
"
V 5.1
T 09 Skand.
024401
V 3.0
020622
"
"
As of V 6.0 with KC V 2.2
V 6.0
T 11
024860
V 3.0
020622
"
"
V 6.2
024861
V 3.0
020622
"
"

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Table of the EMC MONITOR program versions and all the


available combinations
Prog. Version
V 1.1 (1.0)
V 1.1 (1.0)
V 2.0
V 2.0
V 2.0
V 2.0
V 3.1
V 3.1
V 3.1
V 3.1
V 3.1-S
V 3.1-S
V 3.1-S
V 3.1-S
V 4.0
V 4.0
V 4.0-S
V 4.0-S
V 4.1
V 4.1
V 4.1-S
V 4.1-S
V 4.2
V 4.2
V 4.2-S
V 4.2-S
V 4.3
V 4.3
V 4.3-S
V 4.3-S
V 4.4
V 4.4
V 5.0
V 5.0-S
V 5.1
V 5.1
V 5.1-S
V 5.1-S
V 6.0
V 6.0-S
V 6.2

CP 1
Video
Monitor
Monitor
Text Version Id. No.
Prog. Version Id. No.
Monochrom Color
T 01-T 03 EG 020150
V 1.1 (1.0)
020131
"
T 02 Skand. 020150
V 1.1 (1.0)
020131
"
T 06 EG
020151
V 3.0 (2.0)
020620
"
T 06 EG
020151
V 3.0 (2.0)
020621
"
"
T 07 Skand. 020152
V 3.0 (2.0)
020620
"
T 07 Skand. 020152
V 3.0 (2.0)
020621
"
"
T 08 EG
020155
V 3.0 (2.0)
020620
"
T 08 EG
020155
V 3.0 (2.0)
020621
"
"
T 09 Skand. 020156
V 3.0 (2.0)
020620
"
T 09 Skand. 020156
V 3.0 (2.0)
020621
"
"
T 08 EG
020157
V 3.0 (2.0)
020620
"
T 09 Skand. 020157
V 3.0 (2.0)
020621
"
"
T 08 EG
020158
V 3.0 (2.0)
020620
"
T 09 Skand. 020158
V 3.0 (2.0)
020621
"
"
CP Version no longer available = see IP 2 / 97 =
T 08 EG
023590
V 3.0
020622
"
"
T 09 Skand. 023600
V 3.0
020622
"
"
T 08 EG
023610
V 3.0
020622
"
"
T 09 Skand. 023620
V 3.0
020622
"
"
T 08 EG
023591
V 3.0
020622
"
"
T 09 Skand. 023601
V 3.0
020622
"
"
T 08 EG
023611
V 3.0
020622
"
"
T 09 Skand. 023621
V 3.0
020622
"
"
T 08 EG
023592
V 3.0
020622
"
"
T 09 Skand. 023602
V 3.0
020622
"
"
T 08 EG
023612
V 3.0
020622
"
"
T 09 Skand. 023622
V 3.0
020622
"
"
T 11A EG
023593
V 3.0
020622
"
"
T 11B Skand. 023603
V 3.0
020622
"
"
T 11A EG
023613
V 3.0
020622
"
"
T 11B Skand. 023623
V 3.0
020622
"
"
T 12a
023594
V 3.0
020622
"
"
T 12b
023604
V 3.0
020622
"
"
As of V 5.0 with PMS - Card and KC V 2.1
T 08
024330
V 3.0
020622
"
"
T 08
024340
V 3.0
020622
"
"
T 08 EG
024331
V 3.0
020622
"
"
T 09 Skand.
024411
V 3.0
020622
"
"
T 08 EG
024341
V 3.0
020622
"
"
T 09 Skand.
023421
V 3.0
020622
"
"
As of V 6.0 with Kc 2.2
T 11
024840
V 3.0
020622
"
"
T 11
024850
V 3.0
020622
"
"
024841
V 3.0
020622
"
"

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Mon gb 01 04.04.2005

Extensions to Monitor machines ( Drupa 90 version )


1. Program extension to V 5.0 or V 5.1
2. PMS System
As of machine 155 EM - EMC Monitor no. 6021001 (April 1990) the program version V 5.0 was
employed on CP1. Shortly after that, this program was modified to version V5.1. This change involves
the boards CP 1, KC, BTM and PI
EM - Monitor

V 5.0
V 5.0
V 5.1
V 5.1

CP 1
T 08
T 09
T 08
T 09

024350
024400
024351
024401

V 3.0
V 3.0
V 3.0
V 3.0

Video
020622
020622
020622
020622

Monochrome Color
Monochrome Color
Monochrome Color
Monochrome Color

020622
020622
020622
020622
020622
020622
020622
020622

Monochrome Color
Monochrome Color
Monochrome Color
Monochrome Color
Monochrome Color
Monochrome Color
Monochrome Color
Monochrome Color

EMC - Monitor
V 5.0
V 5.0
V 5.0. S
V 5.0 .S
V 5.1
V 5.1
V 5.1.S
V 5.1.S

T 08
T 09
T 08
T 05
T 08
T 09
T 08
T 09

024330
024410
024340
024420
024331
024411
024341
024421

V 3.0
V 3.0
V 3.0
V 3.0
V 3.0
V 3.0
V 3.0
V 3.0

This modification of program versions V 5.0 and V 5.1 cause the following changes to the previously
used control boards.
1.1 The PI board, id. no. 024080, is no longer equipped with a slot for interchangeable memories, because
the program memories are now integrated into the CP 1 computer board. All the other functions on the
PI board remain unchanged. For service purposes, the former PI boards can be used, too.
1.2 Keyboard controller KC, id. no. 023830 is a new development. Apart from the well known features of
these boards a new slot for the PMS card has been installed.
The additional red colored LED
V22 which is designated R / W (Read / Write) indicates the reading and writing functions of the PMS
card. The mechanics of the KC has also been changed. - see BTM 1.3 The BTM control unit, id. no. 023810 (EMC), 024360 (EM), has also been modified and can therefore
no longer be used on machines with the older program versions. The complete keypad has been
displaced about 10 mm downward in order to have enough space for 10 additional function keys, which
are not used at the moment, however.
Please note! The BT DNF has also been mechanically changed.
2. The PMS - Card, POLAR Memory System, id. no. 228243, is a check-card size memory card offered
as an optional unit. This PMS card is a 3-V lithium battery-backed RAM which has a capacity of 99
programs. This memory serves to transfer programs from machine to machine, from computer to
machine or simply to store cutting programs.
It is no main memory comparable to our RSP interchangeable memory.

-9-

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Excerpt from IP 2 / 97
Reduction of program versions for EM / EMC Monitor machines
The CP 1 boards listed below, which are meant for machines without PMS card, replace the boards with
software versions V 1.1 to V 3.1.S, inclusive. The reduction of variants achieved in this way makes stock
keeping easier and organization clearer. For any conversion, please observe the compatibility of the Video
card you use in connection with the corresponding program status of the CP1.
If the machine still contains a European standard size video p. c. board, remember to remove the guide tie
in the CU before installing the new video board (double European standard size). Please return any defective
or replaced boards to our spare parts department.

Current program versions of CP 1 boards


( which replace the versions V 1.1 to V 3.1 S inclusively )
Machine
EMC
EMC
EM
EM

Board
CP1
CP1
CP1
CP1

Version
V 4.4
V 4.4
V 4.4
V 4.4

Text
T12a
T12b
T12a
T12b

Id. No.
023594
023604
023774
023784

Board
Video 2
Video 2
Video 2
Video 2

Text T 12 a for program version V 4.4


1 = GERMAN
D
2 = ENGLISH
GB
3 = FRENCH
F
4 = SPANISH
E
5 = ITALIAN
l
6 = PORTUGUESE
P
7 = DUTCH
NL
8 = JAPANESE
J

Id. No.
020622
020622
020622
020622

Comment
color, monochr.
color, monochr.
color. monochr.
color. monochr.

Text T 12 b for program version V 4.4


1 = GERMAN
D
2 = ENGLISH
GB
3 = FRENCH
F
4 = TURKISH
TR
5 = DANISH
DK
6 = NORWEGIAN
N
7 = SWEDISH
S
8 = FINNISH
SF

As of now all the CP 1 boards which are returned for repair will be retrofitted to program
status V4.4 or more recent, or replaced by new boards of the relevant program status. If a new
graphics card is also necessary for the conversion of the machine at the customers please
order this card separately.

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Power supply
Power Module (PM)
The Power Module accommodates the power supply components for the machine control system and
includes the main distribution board (PMD), fuse board ( PMF ), control transformer and rectifier component
( PMR ). The three-phase lines from the main and (automatic) star-delta switch are protected by three
fuses of 10 amps, each, in the main distributor. Behind these fuses, the backgauge drive motor, blower
motor, fluorescent lamp for table illumination, and the control transformer are connected.
The transformer is switched on via relay K. 304 on the main distributor. The relay is controlled by the green
Control voltage ON button on the right top of the front panel when the (automatic) star-delta switch is
changed over to the delta position. When the machine is switched off by pressing the button - 292 0
relay K 304 drops out and turns the transformer off.
( see circuit diagram 115 EMC 3102 a/c circuit 2 - 24 as well as 45 - 49 )
Adaptation of the control voltage to varying mains voltages can be carried out on the main distributor.
The primary circuit of the transformer can be operated with voltages of 180V to 260V which are supplied
either between two phases (220-V position ) or between a phase and the neutral (380-V position).

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The control transformer generates the following voltages on the secondary


circuit :
Secondary voltage

Application

PMF fuse

32 V

PS plug-in board
+5 V, +24 V and +12 V

F 1 = 6.3 A

11.5 V

+9 V for control unit


and keyboard computer

F 2 = 4.0 A

12.5 V

cutting-line indicator lamp

F 3 = 4.0 A

42 V

F 4 = 6,3 A

12.5 V

42 d.c. for magnets


( except for Y 27 + Y 33 )
cutting-line indicator lamp

15 V

not assigned

42 V

42 V control voltage for


contactors of backgauge drive motor

20 V

not assigned

30 V

Fixomat

15 V

Fixomat

F 5 = 4.0 A
F6
F 7 = 1.0 A

F8

The 1-amp fine-wire fuse for the 32 V a. c. blower motors is accommodated on the CUM unit ( top
right).
Control voltages

In order to operate the control system the Power Supply (PS) board generates stabilized d.c. voltages
of + 5 V, + 12 V and + 24 Volt, resp.
The Keyboard Computer ( KC ) and control unit ( BTM ) module is supplied with a voltage of + 9V from
the Power Module ( PM ).
The solenoid valves and lifting magnets in the machine are energized through an unstabilized d.c.
voltage of + 42 Volts ( except Y27 and Y33 ).
At the measuring socket on the bottom edge of the SK board you can measure the stabilized voltage of
+42Vd.c
In unloaded condition the value is approx. 55 V d. c.
(consequently, no magnet is energized)

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Description of plug-in boards


Power Supply ( PS )
The Power Supply board (PS) provides three stabilized voltages:
+5 volts
+12 volts
+ 24 volts

Tolerance:
Tolerance:
Tolerance:

5.08 -5.12 volts


11.4 -12.6 volts
23.7 -24.3 volts

Each voltage is assigned a green light-emitting diode and a measuring socket on the front of the board.
These voltages are not adjustable.
In order to ensure a defined start of the control system after the control voltage has been connected the
board generates a reset signal, which can be controlled by the red light-emitting diode V3.
The LED is usually off during operation. It only lights briefly when the control voltage is turned on and
off.

- 13 -

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Central Processor ( CP 1 )
The 16-bit computer board determines all the machine cycles and operating features through the
EPROM-stored processor program The remaining plug-in cards are connected to the computer by
means of two separate bus systems. The front side is equipped with four connectors for serial
interfaces, where the keyboard computer, the printer and the peripheral units can be connected.
Battery-buffered RAM components serve to store the variable machine data (e. g. brake
afterrun, most recent program and step numbers, cut counter, etc.). The relevant lithium-type
3.5-V battery is accommodated on the board. The battery voltage must not drop below 3 V.
When the pushbutton on the front side of the board is pressed, a computer reset is triggered which is
similar to turning on the control voltage again. While the machine is in operation the LED in this button
is lit and indicates that the microprocessor on the board is working. On those boards which are
delivered as spare parts the lithium battery is taken off to prevent any unnecessary discharge.
As of program version V 5.0 ( see page 07 ) the program memories A and B are integrated into
the CP 1 board! It has a capacity of 99 programs with 1528 memory locations per memory.

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Positioning Interface ( PI )
The Positioning Interface board includes all the assembly groups which are required for the backgauge
movement:
- counter chain for forward and backward pulses of the linear measuring system
- preselector for setting the reference position
- inputs of the single-hand control switches (S10, S14, S18)
- inputs of the table limit switches
- outputs of the table motor and brake lifting solenoid controls
- slots for the RSP memories ( only on V 1.0 to V 4.4 )
The S 7 selection switch serves to preset the preferred language and measuring unit to be used after
the machine is turned on, for instance when the battery has been replaced and the data on the CP1
board has been lost. The counter monitor can be connected to the three plugs A, B, C located on the PI
board.
The PI boards as of id. no. 020141 are no longer furnished with these 3 plugs, because the counter
chain is integrated in a special module (Gate Array). The V16 and V17 light-emitting diodes have also
been omitted.
As of CP 1 Version V 5.0 we employ the PI board with id. no. 024080. The slots for the
interchangeable memory have been omitted. For test purposes the board can also be employed with
older CP 1 versions.
Setting the preselector switch S 7
( only on program versions V 1.0 V 5.1 )
Language No.

Switch No.

1 German
2 English
3 French
4
5
6
7
8
9
10

7.5

7.4

7.3

7.2

7.1

not assigned
not assigned
not assigned
not assigned
not assigned
not assigned
not assigned
not assigned
not assigned
not assigned

OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON

OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF

OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF

OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON

The languages as of no. 4 are available on the CP 1 board depending on the text version.

Measuring system
centimeter
millimeter
inches
sun

Switch No. 7.8


OFF
OFF
ON
ON

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7.7
OFF
ON
OFF
ON

7.6
not assigned
not assigned
not assigned
not assigned

Accompanying material for technical training course

Mon gb 01 04.04.2005

PI PLUG-IN BOARD
LED No.
V 15
V 16*
V 17*
V 18
V 19
V 20
V 21
V 22
V 23
V 24
V 25
V 26
V 27
V 28
V 29
V 30
V 31
V 32
V 33

Color

Meaning

red

lights about 0.5 sec. when


reference point is overrun
forward counting
flashes during backgauge movement
table limit switch, rear
false clamp plate I
(S6)
false clamp plate Ii
( S 218 )
Fixomat active
pedal actuated
( S 390 )
switch forward
( S10 )
reverse switch
( S14 )
manual precision adjustment ( S18 )
backgauge motor return movement
backgauge motor fast
spare
spare
spare
table limit switch, front
backgauge motor ON
brake lifting solenoid ON
( Y 17 )

red *
red *
yellow
yellow
yellow
yellow
yellow
yellow
yellow
yellow
red
red
red
red
red
yellow
red
red

Ground state
OFF
ON / OFF *
ON / OFF *
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
OFF

* no longer on PI boards as of id. no. 020 141


yellow = input red output
Setting the selection switch S 7 as of program version V 6.0 ( T 11 )
Language No.
1. German
2. English
3. French
4. Spanish
5. Italian
6. Dutch
7. Danish
8. Finnish
9. Swedish
10. Norwegian
11. Portuguese
12. Japanese
13. Turkish

Switch No.

7.5
not assigned
not assigned
not assigned
not assigned
not assigned
not assigned
not assigned
not assigned
not assigned
not assigned
not assigned
not assigned
not assigned

7.4
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON

7.3
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON

7.2
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF

7.1
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF

Adjustment of measuring unit as described on the previous page.

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Positioning Interface ( PI )

Connectors X 1 and X 2 are no longer applicable on PI 024080 as of CP 1 version V 5.0

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Linear measuring system (LMS)


While the backgauge is moved the reading head of the linear measuring scale delivers 0 and 90-degree
pulses which are then quadruplicated by the PI board. Depending on the direction in which the backgauge
moves, these pulses are counted up (return) or down (advance), respectively, in the counter chain. By
quadruplicating the pulses a measuring accuracy of one counting pulse in 0.01 mm of backgauge travel is
obtained. Every time the reference point
is overrun (approx. at the center of the
scale) a pulse loads the value set by
selector switches S1..S6 into the
counting chain
(reference measurement). A basic
condition for perfect counting pulses is
a proper calibration of the measuring
sledge with regard to glass ruler, i. e.
the scanning grating in the measuring
slide must be parallel to the counting
bar on the glass ruler.
These counting bars are not visible with
the naked eye, because they are 0.02
mm wide. The distance between two
counting bars is also 0.02 mm. You can
merely perceive the bars as gray
colored stripes, about 8 mm high, on
the glass ruler. The mechanical
adjustment of the measuring slide and
the electrical setting of the counting
signals are carried out in the factory
using special instruments when the
linear measuring scales are produced.
The mechanical setting of the reading
head in the measuring system at the
customers can be made with the
adjusting set, id. no. 020364.
This adjusting set allows to check if the
reading head delivers counting pulses or
if it really detects the reference point. You
can also measure if the setting pulse for
the counter chain is located in the center
of the reference signal. This is indicated
by the bar graph on the adjusting
instrument. You can readjust the pulse
by means of the adjusting screw at the
measuring slide, which will also readjust
the parallel position of grid plate and glass
ruler. The reference testing instrument
id. no. 023798 is available for verifying
the deviations (also temporary deviations) upon backgauge positioning, as well as for inspecting the ruler
cable.

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Linear measuring system (LMS)

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Interchangeable memory
The interchangeable memory is a p.c. board fully-enclosed in a plastic housing which contains two batterybacked RAM components (memories). The memory capacity of 1,664 records can be distributed to 99
programs. Depending on the location on the PI board the memory indicates either A or B on the screen as
an identification. At the factory the battery is designed for an operation of a min. 5 years. The 3.5-V lithium
battery is accessible after both housing covers have been opened. It can be replaced with the control
voltage switched on.

Battery voltage should not fall below 3 V, because program data may be lost otherwise.

Motor Control Unit ( MCM unit )


The change-pole three-phase current backgauge motor is switched by three contactors
located on the MCM unit:
K 11 M active = high number of revolutions
K 12 M active = advance direction of rotation
K 15 M active = reverse direction of rotation
During the backgauge movement the brake
lifting solenoid of the backgauge motor is
energized. In order to ensure a fast lifting of the
brake the 24-V d. c. coil of the brake lifting
solenoid is briefly supplied with a voltage of
approx. 50 V from a capacitor (C 1).
The control signals for the contactors and the
brake lifting solenoid are generated on the
Positioning Interface board and supplied to the
MCM unit via a flat-belt cable.
Backgauge motor and blower motor are
protected against overload and short circuit by
one overload switch, each.

* Auxiliary relay
K 12 = backgauge motor ON
K 15 = Backgauge motor forward / backward
K 11 = backgauge motor fast / slow

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Accompanying material for technical training course

Mon gb 01 04.04.2005

Cutting circuit (SK)


The fail-safe sequence of a cutting cycle is ensured by the cutting circuit board. During the clamping and
cutting processes, the hardware logic of this board and the software contained in the Central Processor
generate instructions controlling the activation of the hydraulic valves and the safety bolt. The air supply of
the machine table is controlled with the help of one relay, each, for the solenoid valves of the front and rear
table air supply. The light barrier ( identical infrarred light barrier as on the EMC II machines ) only interferes
with the cutting circuit. The light barrier amplifier receives the test signal ( LST ) from board SK and
supplies the enabling signals LS and LS.
For testing purposes the LS Simulator test plug, id. no. 019548 can be used instead of the light
barrier.
For servicing the control system can be operated without cutting circuit board. In this case, the features
clamping, cut, mechanical cutting-line indicator and connect air supply are not available. After switching
on, the message enable cut buttons is displayed on the screen. Both the manual and automatic control
of the backgauge drive (and the operating function via keyboard) are possible.
At the socket on the bottom edge of the board you can measure the unstabilized voltage of +42V
d.c. If no solenoid is energized the measuring value is approx. 55 V d. c.
In order to monitor the control conditions the cutting circuit board is equipped with LEDs on its
front side:
LED

Color

V83
V84

red
red

V85
V86
V87
V88

red
red
red
red

V89

red

V71
V72
V73
V74
V75
V76
V77
V78
V79
V80
V81

yellow
yellow
yellow
yellow
yellow
yellow
yellow
yellow
yellow
yellow
yellow

V82

yellow

Meaning

Ground state

safety bolt
Y. SB ( 42V from K1 )
cycle for cutting circuit transformer
= clamping =
( Y 27 )
light barrier test positive
cut buttons pressed correctly
energize safety bolt
logic error in cutting circuit
= discrepancy =
cycle for cutting circuit transformer
= cut =
( Y 33 )
safety bolt in resting positionB.SB E
safety bolt unlocked
B.SB A
Cut button, right, break contact
S 28a
Cut button, left, break contact
S 28b
Cut button, right, make contact
S 28a
Cut button, left, make contact
S 28b
knife upstroke
S 22a
knife descending
S 22b
Clamp at top
B 29
inching mode (knife change)
S 340
pedal actuated
S 309
(activation Y 315 of SK)
Air table switch
S 87

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OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
ON
OFF
OFF
OFF
ON
ON
OFF
OFF
OFF

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Cutting circuit board (SK)

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Cutting circuit with two-channel hydraulic system


For machine models 92,115,137,155, 176 EM / EMC Monitor
which are sold in Germany and England.
The following components are new (Feb. 1990)
Electrical System
1. control transformer BV 6328 id no. 228755
2. 4 proximity switches 0.8 mm.
3. MHY control p. c. board with housing.
4. Adapters of plugs CU 2, 6, 9, 15 on plug 431.
5. 2 connecting cables with plugs for solenoid valves Y 27a and Y 33a.
Mechanical system
1. Hydr. control unit with 2 additional recirculating ball solenoid valves Y 27a and Y 33a
2. 4 cam disks.
3. 1 holding sheet metal for the proximity switches.
The 4 cam plates are numbered from 1 4 and connected by pins. They can be adjusted a max. 20
mm, as before, for setting the top dead center. The proximity switches are also numbered from 1 4
and mounted at a distance of 0.6 0.8 mm from the cam plate.
Knife upstroke control
The MHY control p. c. board which is mounted in a housing on the rear of the machine frame is
furnished with a voltage stabilization of its own: for 24-V d. c. voltages for the proximity switches and 5
V d. c. for the electronic components as well as relays K1 and K2.
The 24-V a. c. supply voltage for the MHY control board is supplied by the control transformer via
plugs X1, 14, 15. It is protected with 1 amp by a circuit fuse. The individual signals of the four proximity
switches are evaluated in two electronic modules. Via 2 transistors the K1 and K2 relays for the knife
upstroke control are activated.
Control of the two-channel hydraulic system
Parallel to the solenoid valves Y27 and Y33 ( adapter plug no. 6 ) two relays K3 and K4 are also
activated. By means of their normally open contacts the solenoid valves Y 27a and Y 33a are energized
with a separate voltage supply of 42V d. c. CU 2.14 and 15.
The relays K3 and K4 for controlling the additional solenoid valves Y 27a and Y 33a are positively driven
and self-monitoring.
The NC contact of relay K3 is looped into the circuit of the safety bolt resting position B.SB E ( plug CU
9.8 ). The NC contact of relay K4 is looped into the circuit of cut button S 28a NC contacts (plug CU
15.8).
In case of a self monitoring error the following error messages are displayed:
Release cut buttons
Unlock mechanical lock

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( Relay K 4 of MHY )
( Relay K 3 of MHY )

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Mon gb 01 04.04.2005

LIGHT BARRIER ( LS )
The light barrier works with invisible infrared light of a wavelength of 960 nm and consists of the following
parts: transmitters, receivers and the light barrier p.c. board (LS). The light barrier p.c. board is accommodated
in the left-hand light barrier housing, where the receivers are also located, while the transmitters are in the
right-hand light-barrier housing. For the voltage supply the LS board has a +12-V d.c. stabilization which
is operated at +24 Vd.c.
The transmitting diodes generate light pulses at a cycle of approx. 1,000 Hz. Three transmitting diodes,
each, are connected in series, with the transmitting diodes 1, 3 and 5 on one hand and 2, 4 and 6 on the
other hand are working in antiphase. The current running through the transmitting diodes can be checked
with the help of 2 red- colored LEDs (V13 fir transmitters 1, 3, 5 and V15 for transmitters 2, 4, 6) on the LS
board. The voltage drop to be measured for each transmitting diode is approx. 1 V d.c. Any error occurring
at the oscillator output which is in phase opposition will be indicated by the LED V1 lighting up. On the
receiver side the incoming light pulses are converted into electric signals by photo pin diodes and then
digitized by downstream amplifiers. The decoding circuitry has a double setup and works in parallel.
The connection compares receiver signals with regard to their frequency and phase positions with the
corresponding transmitter signals and generates an output level in case of conformity. The two output
levels are inversed so that short circuits in the outputs can be detected. The output levels are indicated by
2 light emitting diodes visible from outside (V10 red and V8 green). In order to localize any channel that
has been broken down the LS board is equipped with light-emitting diodes (V2 V7) which are glowing
slightly with normal operation, but are brightly illuminated when a channel fails.
The light barrier housings are adjusted at the factory which ensures that a reproducible installation is
ensured during assembly. However, should it be necessary to readjust one of the rays, the p.c. boards of
the transmitting and receiving diodes can be shifted to adjust the focus precisely, after the fastening
screws have been loosened. In the proper position the a.c. voltage at the receiver diode reaches a maximum
value.
The minimum value is 150 mV a.c., measured at the individual receiver diodes.
The correct adjustment of the light barrier can be checked with the service jumper inserted on board LS,
either by measuring the voltage at each of the receivers or by triggering various cuts.
Before each clamping process or knife movement the Central Processor (CP1) initiates a light-barrier test
where the transmitting diodes are briefly switched off. Within 40 ms the light barrier must respond with the
condition interrupted. Otherwise, the light barrier test is considered as not successful and the relevant
error is shown on the display.
Caution!

The red LED V10 is part of the safety circuit of the light barrier.
In case of a defect of the LED the green LED V8 will also go out,
which causes the cutting and clamping functions to be locked.

The two LEDs V17 and V18 are off when the light barrier is working perfectly.
They monitor the two output levels of the light barrier to the SK board.
If these levels are not inversed the LEDs will light up.
In this case, both clamping and cutting functions are locked.

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Video Controller (VID)


The Video Controller (VID) plug-in board generates the signals for the horizontal and vertical synchronization
required to activate the monitor, and the video signal for the screen content. These pieces of information for
the monochrome monitor are combined to a composite video signal on the board and supplied to the
monitor through a 75-ohm coaxial cable. The two BNC plugs on the front side of the board can be used
alternatively.
For the color monitor the Video Controller board supplies a video signal in the form of an RGB signal which
is supplied at the 9-pin socket on the on the front side of the board. A cable and the relevant plugs connect
it to the monitor. A color monitor can only be operated if the necessary Video Controller plug-in board is
available (see section 1.1).
During machine operation the Video Controller receives the necessary information about the screen content
from the Central Processor (CP 1). When the control voltage is switched on the Video Controller generates
a test pattern which consists of horizontal and vertical lines and is displayed when the Central Processor
(CP 1) does not supply any information (for example: CP 1 not plugged in).
The test pattern is required for setting the monitor. On Video Controller boards equipped with the red
colored LED V5 the diode must light when the control voltage is ON. When it goes out, the Video Controller
must have suffered a defect which locks the Central Processor and therefore all the functions.

Monitor ( CRT )
All the monitors used with Polar machines are operated at a service voltage of 220 V, 50 - 60 Hz. The
voltage supply is ensured by the Power Module and taken from the primary circuit of the control transformer.
A troublefree function of the monitors is only ensured with the proper voltage supply. Therefore, make sure
to adjust the machine to the available mains voltage during the machine assembly. An insufficient voltage
may result in fluctuating images. The adjustment is made by re-plugging the jumper (200 260 V) on the
fuse board in the Power Module.
In the case of a failure or defect, the monitor should be dismantled from the housing and replaced. You
should not perform a correction of the setting, because some of the components remain at high potential.
Furthermore, a modified setting may result in an inadmissible release of X-radiation.
The monitors are hung up and connected to the housing by means of vibration absorbers.
The rear of the housing has a turning knob for adjusting the brightness.
Keyboard Computer ( KC ) and control unit ( BTM )
The Keyboard Computer (KC) monitors all the keys of the control unit ( BTM ) and the switches for
distortion, label correction and retarding of the cutting cycle. Any actuation of the controls is reported
serially to the Central Processor. The internal supply voltage of +5.10 V is generated from the supplied
voltage of +9V and can be checked with the green LED and two measuring sockets.
With the potentiometer located beneath the measuring sockets the value of +5.1V can be
readjusted, if necessary.

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During operation the red V19 LED computer activated is flashing every second.
The keyboard computer has a self-testing routine for trouble shooting.
(see Service Information)
The KC and BTM assemblies are not required for carrying out the basic functions of the machine.
For service purposes the control system can be run without this assembly.

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Timer board (CLK)


The CLK (Clock) board contains a timer module. When the control voltage is turned off this module is
supplied from a 2.4-V lithium battery.
The CLK board is connected to the CP1 board through the P bus. It is required as a time base for
generating the production report. The TP1 test point is only required to calibrate the clock frequency for
the timer module. On those boards which are delivered as spare parts, the lithium battery is taken off to
prevent any unnecessary discharge. The CLK board is not essential for the functioning of the machine
control system.
For service purposes the control system can be operated without this board and consequently, without
the time. In this case, the production report feature is not possible.
On cutting machines equipped with the optimized high-speed backgauge the Servo board is
plugged in instead of the CLK board. The Servo board includes the timer module and carries
out the functions of the CLK board.

PMS CARD
The PMS - Card, POLAR Memory System, id. no. 228243, is a check-card size memory card offered as
an optional unit. This PMS card is a 3-V lithium battery-backed RAM which has a capacity of 99 programs.
This memory serves as a data medium for cutting programs from machine to machine, from Compucut to
machine or simply for saving and storing recurrent cutting programs. The PMS Card is no main memory
comparable with our RSP interchangeable memory.

New knife change as an optional equipment


POLAR EM / EMC - Monitor 92 / 115 / 137 / 155
As of POLAR 137 EM / EMC - Monitor, machine serial no. 6041201, the new knife change system is
available as an optional equipment.
The following components are new:
1. front panel
2. knife bar
3. knife
4. knife screws
5. knife wrench
6. knife adjusting cam at the con-rod
7. automatic stop at bottom dead center

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All the actions for the new knife change are carried out from th front
side. Both the knife bar and con-rod adjustments are made in the
factory and must not be changed. The knife has to be installed and
removed precisely according to the enclosed operating instructions.
When adjusting the knife, draw it slightly nearer with the screws,
then tighten the knife support screws (left side first).
The knife must not tilt upward (see sketch).

If the knife does not cut the material perfectly after some cuts have been made, it may be adjusted
deeper at the knife adjusting cam by means of a knife wrench. Before doing so, push the cam lock
upward (see sketch). The knife adjusting cam has 9 catch positions and must be reset to 0 with every
knife change (turn counterclockwise).
When the cam lock is pushed upward no cut can be performed.

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Parts list no. 1


Title

Position

KC
CRT
CU
SK
CP1
PI
VID
PS
EB
RSP
LS
LSV
LMS
MCM
MHS
PM
PMD
PMF
PMR
SDS
A1
B. SBA
B. SBE

Frame
Frame
Frame
CU
CU
CU
CU
CU
CU
CU
Frame
Frame
Table
Frame
Cable duct
Frame
PM
PM
PM
Frame
Frame
Frame
Frame

BTM. S1
BTM. S2
BTM. S3
B29
CP1. G1
CP1. S1
CRT. F
CRT. R1
CU. F1
E 39
E 42a
E 42b
K 1M
K 3M
K 5M
K 3T

BTM
BTM
BTM
Frame
CP 1
CP 1
CRT
CRT
CU
Frame
Frame
Frame
SDS
SDS
SDS
SDS

Function
Keyboard Computer
VDU
Control unit motherboard
Plug-in board: Cutting circuit
Plug-in board: Central Processor
Plug-in board: Positioning Interface
Plug-in board: Video Controller
Plug-in board: Power Supply + 5 / 12 / 24 V d.c.
Cutting circuit transformer board
RAM memory
Light barrier board
Light barrier transmitter distributor board
Linear measuring system
Backgauge motor control
Knife upstroke control
Power supply unit
Power supply unit distributor board
Power supply unit fuse board
Power supply unit rectifier board
Automatic star-delta starter
Mains supply
Control sensor electro-mech. non-repeat device out of action
Control sensor el.-mech. non-repeat device in locking
position
BCD switch: clamping time adjustment
Shaft encoder: distortion
Shaft encoder: Label correction
Proximity switch clamp at top
Battery - voltage source for data saving
Reset button
2.5-amp fuse
Potentiometer: brightness control
1-amp fuse for ventilators (M.V a / b)
Fluorescent lamp with starter
Lamp for optical cutting-line indicator
Lamp for optical cutting-line indicator
Mains contactor
Star contactor
Delta contactor
Time-delay relay

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Parts list no. 2


Title

Position

K11
K12
K15
K11M
K12M
K15M
K22 a/b
K304
KC.B1
KC.S1
L38
M3
M17
M93
M.V a
M.V b
PM. C1
PM. C2
PM. C3
PM. V1
PM. U2
PM. V3
PMD. Z1
PMD. F1
PI. K1
PI. S7
PMF. F1
PMF. F2
PMF. F3
PMF. F4
PMF. F5
PMF. F6
PMF. F7
PMF. F8
PI. S1
PI. S2
PI. S3
PI. S4
PI. S5
PI. S6
PS. F1
PS. F2
Q2
Q92
Q96

MCM
MCM
MCM
MCM
MCM
MCM
MHS
PMD
KC
KC
Frame
Frame
Table
Table
CU
CU
PM
PM
PM
PM
PM
PM
PMD
PMD
PI
PI
PMF
PMF
PMF
PMF
PMF
PMF
PMF
PMF
PI
PI
PI
PI
PI
PI
PS
PS
Frame
MCM
MCM

Function
Relay: Table motor high speed
Relay: Motor ON
Relay: Return stroke
Contactor: Table motor high speed
Contactor: advance movement
Contactor: Return stroke
Auxiliary relay for cutting and clamping
Relay Control voltage ON
Signal horn
Key: Self test

Fluorescent lamp ballast


main motor
Backgauge motor
Blower motor
Ventilator
Ventilator
Filter capacitor for + 42 V d.c.
Filter capacitor for +9 V d.c.
Filter capacitor for + 5 / 12 / 24 V d.c.
Rectifier for + 42 V d.c.
Rectifier for +9 V d.c.
Rectifier for + 5 / 12 / 24 V d.c.
Mains filter
Main fuses 3 x 10 amps
Switching contact with backgauge motor brake
Switches: Language / measuring unit presetting
Fuse 6.3 amps for 32 V a.c.
Fuse 4 amps for 11.5 V a.c.
Fuse 4 amps for 12.5 V a.c.
Fuse 6.3 amps for 40 V a.c.
Fuse 4 amps for 12.5 V a.c.
Fuse 1 amps for 15 V a.c.
Fuse 1 amps for 42 V a.c.
Fuse 1 amps for 20 V a.c.
Coding switch for reference position 1/100 mm
Coding switch for reference position 1/10 mm
Coding switch for reference position mm
Coding switch for reference position cm
Coding switch for reference position dm
Coding switch for reference position m
Fuse 4 amps for +24 V d.c.
Fuse 1.4 amps for +12 V d.c.
Main switch
Overload switch for blower motor (M93)
Overload switch for backgauge motor (M17)

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Parts list no. 3


Title

Position

RSP. G1
S6
S7
S8
S9
S 10
S 13
S 14
S 18
S 22 a
S 22 b
S 28 a
S 28 b
S 41
S 87
S 217 a

RSP
pressure clamp
Table
Table
Table
Table
Table
Table
Table
Gearbox
Gearbox
Table
Table
Frame
Table
Table

S 217 b

Table

S 218
S 292
S 309
S 340
S 360 a / b

pressure clamp
Frame
Frame
Frame
Table

S 390
SDS. F2
SK. K1

Table
SDS
SK

SK. K2
SK K3
Tr
V 35
V 36
Y 17
Y 27
Y 33
Y 94
Y 94a
Y 315
Y SB

SK
SK
PM
Frame
Frame
Table
Frame
Frame
Table
Table
Frame
Frame

Function
Accumulator - voltage source for data saving
False clamp plate contact
Switches: Changeover of advance speed fast slow
Limit switch with false clamp inserted
Limit switch advance movement
Switch backgauge brake OFF / advance movementON
Reverse limit switch
Reverse button
Switch backgauge brake OFF
Limit switch cutting and clamping
Limit switch cutting and clamping
Button cutting and clamping
Button cutting and clamping
Change-over switch for cutting-line indicator
Button Air supply ON
Limit switch advance movement with first additional false
clamp plate
Limit switch advance movement with second addit. false
clamp plate
False clamp plate contact with additional narrow false clamp
Button drive and control voltage ON
Pedal switch (clamp)
Switch for knife change
Forward limit switch with inserted false clamp plates
and Fixomat
Pedal switch (advance movement)
Protective motor relay for main motor
Relay: Activation of electro-mechanical non-repeat device( Y.
SB )
Relay: Front / rear table air supply (Y94)
Relay: Air supply front table (Y 94a)
Transformer
Light barrier: Light emitting diodes
Light barrier: Receiver photo diodes
Brake lifting solenoid for backgauge motor brake
Solenoid valve for clamping
Solenoid valve for cutting
Solenoid for air table
Solenoid valve for front table air supply
Solenoid for cone valve
Solenoid for electro-mechanical non-repeat device

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EM / EMC - MONITOR
SERVICE INFORMATION
LIST OF ERROR MESSAGES

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Reference material regarding error messages and


status information on EM / EMC Monitor machines
Compilation and description of all significant error messages on EM(C) Monitor machines as of
version 1.0 up to version 6.0, incl.
List of screen texts
ALL DATA UNREADABLE: DELETE
EJECTOR RUN
AUTOTRIM TABLE OPEN
BRK - ERROR
BSY - ERROR 0, 1,2, 3, 4, 5
SWIVEL BACKGAUGE LIMIT POS.
SWIVEL BACKGA. NO REACTION
DUSTERROR
JOGGING MARK
BACKGAUGE LIMIT
EPROM - ERROR
ERROR
WRONG STEP NUMBER
WRONG PROGRAM NUMBER
WRONG PROGRAM ARCHITECTURE
FIXOMAT END-OF-TRAVEL INDIC
ATOR MISSING
FIXOMAT LIMIT SWITCH DEFECTIVE
FIXOMAT FUNCTION LOCKED
ERROR KNIFE TIME PRESETTING
SECONDARY OPERATION
1 / 0 - BUS ERROR
NO PULSES FROM RULER
NO MEASUREMENT AVAILABLE
LIGHT BARRIER INTERRUPTED
LIGHT BARRIER ERROR
MANUAL BACKGAUGE MOVEMENT
POSITION NOT REACHED
MEASUREMENT TOO BIG / SMALL
KNIFE - WIND UP
KNIFE CHANGE
TILTING BACKGAUGE LIMIT
TILTING BACKGAUGE NO REACTION
TURN LABELS.
OPTION NOT AVAILABLE
PMS CARD COMPL. UNREADABLE
PMS CARD WITH DATA ERRORS
PMS CARD NOT INSERTED
PMS CARD RE-READING ERROR
PMS - ERROR
AUTOMATIC POSITIONING ACTIVE
CLAMP NOT AT BOTTOM POS.
CLAMPING TIME INTERRUPTED
PROGRAM DATA ERROR
PROGRAM NOT READABLE
PROGRAM ERROR: DELETE
PROGRAM SAVED

P.42
P.42
P.42
P.42
P.42
P.42
P.43
P.43
P.43
P.43
P.43
P.43
P.43
P.43
P.44

SOURCE PROGRAM UNREADABLE


SOURCE MEMORY UNREADABLE
GO TO REFERENCE POSITION
RE-READING ERROR: DELETE
BACKGAUGE MOVEMENT LOCKED
DELETE STEP
STEP UNREADABLE
STEP ERROR: DELETE
CUTTING CIRCUIT ERROR
CUTTING CIRCUIT INTERRUPTED
CUT BUTTON DEFECTIVE
ENABLE CUT BUTTONS
CUTTING LOCKED
NUMBER OF CUTS HAS BEEN REACHED
SIDE GAUGE LOWERED

P.44
P.44
P.44
P.44
P.44
P.45
P.45
P.45
P.45
P.45
P.45
P.45
P.46
P.46
P.46
P.46
P.46
P.46
P.46
P.46
P.47
P.47
P.47
P.47
P.47
P.47
P.47
P.48
P.48
P.48
P.48

SIDE GAUGE TIME ERROR


P.51
SIDE GAUGE NO LIMIT POSITION SIGNAL P.51
MEMORY CONTENTS UNREADABLE
P.51
MEMORY AREA UNREADABLE
P.51
MEMORY ERROR DELETE
P.51
MEMORY NOT PLUGGED IN
P.51
SAFETY BOLT RETRACTED
P.52
SAFETY BOLT LOCKED
P.52
SAFETY BOLT MONITORING DEFECTIVE
P.52
NON-RETURN VALVE 42V ERROR
P.52
SPV - ERROR
P.52
STAT. CUTTING CIRCUIT ERROR
P.52
TXT - ERROR
P.53
PMS CARD INVALID
P.53
OBSERVE MAINTENANCE INTERVAL
P.53
INADMISSIBLE VALUE
P.53
OVERFLOW
P.53
TARGET PROGRAM DATA ERROR
P.53
ADDITIONAL FUNCTION INADMISSIBLE
P.53
TARGET MEMORY NOT READABLE
P.54

- 41 -

P.48
P.49
P.49
P.49
P.50
P.50
P.50
P.50
P.50
P.50
P.50
P.50
P.50
P.51
P.51

Accompanying material for technical training course

Mon gb 01 04.04.2005

DISPLAY
All data
unreadable
= delete =

CAUSE

REMEDY

Program memory area


(A or B) or PMS card
no longer accessible. The data is
no longer complete or is incorrect.
The affected data areas can
only be cleared, in order to
make a new storage.
Replace. Check voltage supply to
Please note! This message can be
displayed when the machine is first
switched on (put into service) and/or the
first use of a PMS card,
because the A or B

up to V4.4:
Relevant memory or memory area
must be cleared completely. Battery
of removable memory (RSP) must be
checked, Replace removable memory, PI
board check PS board
As of V 5.0:
Completely clear the relevant memory
or memory area. When
using thef memory area A or B check battery of CP1 board, replace CP1
board. Check voltage supply to
PS board. When using the

memories or the PMS card


have not been initialized by
a deleting procedure.

PMS CARD, check the PMS CARD, its


battery, PMS Card slot.

Ejector run
Note

Machine control system has initiated


backgauge movement for programmed
ejector run.

If there is no backgauge movement in spite


of the message: check overload switches
for motors, MCM unit with contactors, check
voltage supply.

Autotrim table
open
Note

AUTOTRIM table is not


closed, or during
closing procedure the light barrier
was interrupted!

Close AUTOTRIM table


Check position of S1 on SFM board,
replace SFM board, check limit switch S364
and relevant cabling.

BRK ERROR

Error in data exchange between


CP 1 board and control panel.
Occurs on machines with V 5.0 and V 5.1
sporadically and without any further
meaning when switched on.

Check voltage supply of PS board,


Check voltage supply + 9 V for KC,
Check compatibility of CP1 board and KC,
correct, if necessary.

BSY ERROR
0, 1, 2, 3, 4, 5

Error which has been detected by operating


system of the program on the CP1
board. Or by pressing the keyboard too
hard.

Check voltage supply of PS board,


verify operation, replace CP 1 board
replace KC

Swivel backgauge
limit position

During manual readjustment or


during the automatic
positioning of the swivel backgauge
the relevant limit position switch
(depending on direction) has been
reached.

Check S 347 and S 348 limit switches


and their cabling. Check CUM.51.6/3
SER.306, SER.314 and 706 plugs.
Replace DNF board, replace SER unit

- 42 -

Accompanying material for technical training course

Mon gb 01 04.04.2005

DISPLAY

CAUSE

REMEDY

Swivel backgauge During manual readjustment


no reaction
or during the automatic
positioning of the swivel backgauge,
there is no true change of the
backgauge position to be recognized.

Check motor for swivel backgauge (M357),


check potentiometer RD and rel. cabling
check PM.409, SER.300,
SER.301, 701, CUM.51, SER.314, SER.304
CUM.313 and 713 plugs, verify setting of
DNF board, replace DNF board,
replace SER unit

DUSTERROR

Data transmission error


between CP1 and COMPUCUT
or AUTOCUT - SPS

Turn the machine off and then switch it on.


replace CPI board(s), check data lines
check Compubox.

Jogging mark
Note

With programmed additional


function JOGGING MARK the operator
tried to make a cut.

Check programming and operation.

Backgauge limit
Note

Backgauge has moved to


active table limit switch relevant forthis direction. Or locking
with rear-table feeding,
rear-table shutoff with light barrier or
switch controlled
rear-table guarding activated.

Check active table limit switch Replace PI


board, check plug CUM.106 ( and
adapter 106a, if available ).

EPROM - ERROR

see TEXT - ERROR

see TEXT - ERROR

ERROR

Internal error message of CP1 board


ERROR 1 = Error detected by
operating system of operating program
of the CP1 board.
ERROR 2 = Text Eprom defective or
not correctly plugged ERROR 3 = Text
Eprom not compatible

Turn the machine off and then switch it on.


Replace CP1 board

Wrong
Step number
Note

Invalid input of a step number


under the functions STEP SELECTION
and INSERT or DELETE
ADDITIONAL FUNCTIONS

Correct your input

Wrong
program number
Note

A program number < 0 or > 98


was input.

Change program number

- 43 -

Accompanying material for technical training course

Mon gb 01 04.04.2005

DISPLAY
Wrong

CAUSE

REMEDY

Error in Eltrotact

Verify program and correct

program architecture
Note

programming.

Fixomat
END OF TRAVEL
INDICAT. MISSING

One of the two lay marks


are in undefined position.

Try to go to limit position


Check S341, S342, S343, S34. switches
and relevant cabling Plugs
CUM.307 and 707 must be checked
Replace DNF board Check Fixomat motors
M345 and M346

Fixomat
limit switch
defective

For one or both lay marks two


limit position switches are
simultaneously signaled as being
actuated.

Check S341, S342, S343, S34. limit


switches and their cabling Check plugs
CUM.307 and 707, replace DNF board

Fixomat Function
locked

Backgauge too close to clamp


for carrying out the Fixornat function
( S360 activated).

Check switches S360, (S360q and S360b),


Check CUM, 106, replace PI board

Error
Knife time preset
( as of V 6.0 )

This error message is shown


when a cut is performed
and a max. preset time of 3 seconds
has been exceeded in the activated
movement of the knife from TDC to
BDC.

Check P2 circuit and relevant activation,


verify solenoid valve Y330, replace SHM
board and SK board.

Secondary operation This mode of operation is


Note
automatically set once the machine is
turned on, if the process
GO TO REFERENCE POSITION,
owing to errors in the area of
drive unit /LMS (or if reference
position on PI board was
incorrectly preset) could not be
performed correctly.
The SECONDARY OPERATION can
also be turned on in the menu GO TO
REFERENCE POSITION by pressing
the C button (in Servo data image
letter A).

- 44 -

Go to reference position
Check LMS and relevant cabling,
check backgauge drive unit
Replace PI board

Accompanying material for technical training course

Mon gb 01 04.04.2005

DISPLAY

CAUSE

REMEDY

I / 0 Bus Error

Input and output signals of


1 / 0 bus svstem cannot be
read correctly.

Turn the machine off and then switch it on,


verify voltage supply; if necessary,
plug-in boards CP1, SK, 5FM, SHM, DNF,
PDR, or CUM must be replaced.

No pulses from
ruler

During motorized backgauge adjustment


no pulses from linear measuring
system have been recorded.

Check MC unit and contactors 11, 12 and


15, check backgauge and relevant
activation, LMS and relevant
cabling must be checked, replace PI board.

No measurement
available

Positioning (2 times equals key)


Verify operation
was initiated without indication of
measurement.
Or automatic advance function was activated
without program measurement.

Note

Light barrier
Cut was aborted because
Check light barrier light barrier was interrupted.

Remove all obstacles from the optical path


Of the light barrier and finish the cut. Check
the LS board, replace, if necessary. Check
light barrier, relevant cabling and setting.
Check CUM.4, CUM.5, LS.-600, LS.601.
and LSV.602 plugs, verify voltage supply
+24 V, check S1 and S2 of tiltable
rear-table guard. Replace SK board

Light barrier
error

Error in light barrier self testing

Check setting of LS, check transmitter and


receiver diodes
Verify +24-V voltage supply, replace LS
board.

Manual backgauge movement


Note

Machine control system has


initiated backgauge movement or
backgauge motor brake was manually
electrically activated.

Check switches S 10, S 14 and S 18


check overload switch for motor, check MCM
unit with contactors
Verify voltage supply

Position
not reached

Difference between required


nominal position and actual
position of backgauge
after a positioning procedure.

Check lubrication of backgauge


Brake afterrun and slow down travel
must be re-determined via function
GO TO REFERENCE POSITION.
Backgauge drive unitand relevant activation
must be checked, Check backgauge motor
brake, if necessary clean and re-adjust it.
Check LMS and relevant cabling
Replace PI board With Servo check zero
point adjustment of ESR device.

- 45 -

Accompanying material for technical training course

Mon gb 01 04.04.2005

DISPLAY

CAUSE

REMEDY

Measurement too
big/small Note

Measurement input does not coincide


with machine size

Check switch 13 Have reference pos.


read in again.

Knife wind up
Note

After switching the machine ON


the knife is not in the
upper resting position.

Switch the machine off and manually turn


the knife back to the TDC by turning the
flywheel.
CAUTION!
Observe safety information.
Check P2 circuit, check gearbox limit switch

Knife change
Note

Knife change function was


switched on.

Check switch S340

Tilting backgauge
limit

During adjustment of
tilting backgauge the direction
Related limit position switch has
Been reached.

Check limit switches S349 and S350 and


relevant cabling. Verify setting of DNF board, Check plugs CUM.51, SER.304,
SER.314 and 704
Replace DNF board, replace SER unit

Tilting backgauge
No reaction

During manual readjustment


or during the automatic
positioning of the tilting backgauge,
no true change of the tilting
backgauge pos. has been detected.

Check motor for tilting backgauge drive M


358, check potentiometer RN and rel.
cabling Check plugs CUM.312, 712,
PM.409, SER.300, SER.302, 702, CUM.51,
and SER.314 Verify setting of DNF board,
replace SER unit, replace DNF board

Turn labels
Note

In an Eltrotact program cycle


sequence it was detected that the last
cut size is smaller than the minimum
size to be approached

Option not
available

An optional function was called


which either is not available or does
not exist at all.

Check if corresponding function is


switched on on the control boards.
Replace the relevant control board.

PMS Card
Compl. unreadable

All the data on the PMS CARD


cannot be read. Please note!
This message can be displayed
when a PMS CARD is used for
the first time because this PMS CARD
has not yet been initialized by
a deleting process.

Set ON / OFF switch on PMS Card to


ON. Verify if PMS Card is
correctly plugged
Initialize board by a complete clearing
Verify battery voltage of PMS Card.

- 46 -

Accompanying material for technical training course

Mon gb 01 04.04.2005

DISPLAY

CAUSE

REMEDY

PMS CARD with


data errors

Part of the data stored on PMS Card


(individual programs and/or steps)
cannot be read.

Check, if PMS CARD has been correctly


inserted.
Delete programs or steps and
enter again. Check battery voltage of
PMS CARD, replace PMS Card

PMS CARD not


inserted

Insert PMS Card into relevant


slot on control unit.

Check, if PMS CARD has been correctly


inserted, replace BTM, replace KC

PMS CARD
re-reading error

Malfunction when writing on


PMS Card. After check of
recorded information an
inequality was detected.

Check, if PMS CARD has been correctly


inserted. Set ON / OFF switch of PMS Card
to ON. Switch any existing write protection
switch on PMS Card off.
Check battery voltage of PMS CARD,
replace PMS Card, replace BTM
replace KC.

PMS ERROR

Data transmission error


between PMS CARD and
CP 1 board.
Please note! Error message
PMS ERROR 4 can also be
issued as a sequence error of
BRK ERROR.

Check data line between KC and CP1.


Check, if PMS CARD has been correctly
inserted. Set ON / OFF switch of PMS Card
to ON position. Switch off any existing
write protection switch on PMS Card
Check battery voltage of PMS Card
Replace PMS Card.
Replace BTM, replace KC

Autom. positioning
active
Note

Machine control system has


initiated backgauge movement.

Remedy, if there is no backgauge


movement In spite of display:Check
overload switch f. motor, check MCM unit
with contactors, verify voltage supply

Clamp not
at bottom
Note

Operating information in KNIFE


CHANGE mode, if operator tries to cut
without having lowered the clamp.

Operate cutting line indicator; if necessary,


verify activation, check B 29
Replace SK board

Clamping time
interrupted
Note

Between cut initiation and


knife movement the cutting or
clamping procedure was aborted
by operator.

Verify setting of clamping time delay


in BTM.

- 47 -

Accompanying material for technical training course

Mon gb 01 04.04.2005

DISPLAY

CAUSE

REMEDY

Program
data error
Program not
readable
Program error
Delete

All the data in a program in


the memory areas of the machine
(A or B) or a program
of the PMS card cannot be read

Remedy up to V4.4:
Completely delete the relevant program
and input again. Check battery of
of removable memory (RSP),
Replace removable memory, replace
PI board. Check voltage supply to
PS board, replace PS board
Remedy as of V5.0:
Completely delete the relevant program
and input again. When using the A or B
memory area, check CP1 board and
battery. Check voltage supply of PS board,
replace PS board.
When using the PMS
Card, check the PMS Card, its battery,
PMS-Card slot, replace BTM
replace KC

Program saved
Note

S. o. attempted to change the program


or delete a protected program.

Un-protect program under Program


Information

Source program
unreadable

While using the functions


COPY PROGRAMS,
COPY ONTO PMS CARD and
LOAD FROM PMS CARD no
data of the source program
could be read.
replace PS board.

Remedy up to V4.4:
Delete relevant program completely
and re-input. Check battery of removable memory, replace removable memory
replace PI board,
Check voltage supply of PS board,
Remedy as of V5.0:
Completely delete the relevant program
and input again. Use of memory area A
or B Check battery of CP 1 board,
replace CP 1 board Verify voltage supply
to PS board, replace PS board.
When using the PMS - Card, verify the
PMS - Card, its battery, the PMS CARD
slot, replace BTM, replace KC

Source memory
unreadable

While using the functions


COPY PROGRAMS,
COPY ONTO PMS CARD and
LOAD FROM PMS CARD the
source memory cannot be read.

- 48 -

Remedy up to V4.4:
Clear the relevant memory or
memory area completely.
Check battery of removable memory,
Replace removable memory, replace
PI board, check voltage supply of
PS board, replace PS board

Accompanying material for technical training course

Mon gb 01 04.04.2005

DISPLAY

CAUSE

REMEDY

Source memory

While using the functions

Remedy as of V5.0:

unreadable

COPY PROGRAMS,
COPY ONTO PMS CARD and
LOAD FROM PMS CARD the
source memory cannot be read.

Relevant memory or
memory area must be cleared completely.
Use of memory area A or B Check battery of CP 1 board, replace CP 1
board. Power supply
check PS board, replace
PS. When using the PMS
Card, check the PMS Card, its battery,
PMS-Card slot, replace
BTM, replace KC

Go to
reference point
Note

When machine is switched on


the parameters required for normal
operation, such as the latest backgauge
position, last brake afterrun value, length
of slow down travel etc. are not available.
This message is output when:
The machine had been switched off
during activated backgauge movement.
A machine is switched on for the first
time, ( commissioning).
The CP1 board had been replaced.
Function has been selected in
PRESET FUNCTION menu.
If this status occurs without any of the
above mentioned conditions the saving
of data might be disturbed when the
machine is switched off.

Check battery on CP1 board


Replace CP 1 board, check switches S 10,
S 14 and S 18. Check keys in BTM for
activating the backgauge movement

Re-reading error
delete

Malfunction when writing on


machine program memory
( A or B ) or onto PMS Card.
When checking the written
information a discrepancy was
detected.

Check battery of CP1 board, replace CP1


board.Check, if PMS CARD has been
correctly inserted. Set ON/OFF switch of
PMS Card to ON position,
Any existing write protection
switch on PMS Card must be turned off,
Verify battery voltage of PMS Card,
replace PMS Card, replace BTM
replace KC

- 49 -

Accompanying material for technical training course

Mon gb 01 04.04.2005

DISPLAY

CAUSE

REMEDY

Backgauge
movement locked

Via SFM board the backgauge


movement was locked.

Locking during rear-table loading


Check rear-table protection with LS or
switch controlled rear-table guarding.
On machines with SERVO: check
backgauge drive and relevant activation,
LMS and relevant Cabling, replace PI board

Delete step
Step not readable
Step Error: delete

In a program of the machine


memories A or B the data of
one or more steps are no
longer readable. The relevant steps are
marked in the menus CUTTING
PROGRAM and PROGRAM
INFORMATION by representing their
contents with lines -.

Delete steps and store again,


re-input the entire program,
if necessary. Check battery of CP1 board
Replace CP 1 board. Check battery
of removable memory, replace removable
removable memory, replace PI board

Cutting circuit
error

SK board detects error in


cutting circuit cycle.

Check cutting circuit (LEDs) replace SK


board

Cutting circuit
interrupted

No agreement between software activation and safety control


channel of SK board.
Sporadic occurrence of this message
does not indicate a malfunction in any
case.

Check if knife is in TDC,


if necessary, wind the knife up. The
Turn machine off and turn the knife
manually to its top dead center
by turning the flywheel
PLEASE NOTE!
Observe safety information.
Check gearbox limit switches. Check
magnet Y.SB, replace SK board

Cut button defective For one or both cut buttons


the input signals for
make and break contacts are
simultaneously recognized as
being activated.

Check cut button and replace, if necessary


( see IP 1 / 91 section 2.20.00e).
Check CUM.15 plug
Replace SK board

Enable cut
buttons

Indicates that at least one cut button


is pressed.

Check cut button and replace, if


necessary
( See IP 1 / 91 section 2.20.00e)
check plug CUM. 15,
Replace SK board. ( Rel. K4 fr. HMY )

Cutting locked

Attempted execution of cut with


activated signal cut is blocked of
SFM board.

Check Autotrim function and waste removal


stroke, check backgauge movement
Replace SFM board.
Replace PI board.

- 50 -

Accompanying material for technical training course

Mon gb 01 04.04.2005

DISPLAY

CAUSE

REMEDY

Number of cuts
has been reached
Note

Cut counter has reached preset value

Cut counter preselection in


survey (8) must be readjusted or
switched off.

Side gauge
lowered
Note

Attempted cut with activated


signal side gauge lowered
SHM board. Automatic knife is switched
off or set back to the step prepared.

Move side gauge up Replace SHM board

Side gauge
time error

Side gauge limit position is not reached


within admissible time.

Check side gauge limit switch


Check side gauge for mechanical
stiffness, replace SHM board, check
locking of rear table loading,

Side gauge
No limit position
signal

When machine is switched on


at least one side gauge is
in undefined position.

Move side gauge up or down. Check


side gauge limit switch,
Check switch positions on SHM board,
replace SHM board, check locking
of rear table loading,

Memory contents
unreadable
Memory area
unreadable
Memory error
Delete

None of the data in a


memory area of the machine (A
or B) or in a memory area
of the PMS card can be read.

Remedy up to V4.4:
Relevant memory or
memory area must be cleared completely.
Check battery of removable memory,
replace removable memory, if necessary,
PI board. Check voltage supply of PS
board, replace PS board
Remedy as of V5.0:
Relevant memory or memory area must
be cleared completely. When memory
area A or B are used. Check battery of
CP 1 board, replace CP 1 board.
Check power supply to PS board, replace
PS board.
When using the PMS
Card, check the PMS Card, its battery,
PMS-Card slot. Replace
BTM and KC, if necessary

Memory not
plugged in
Note

On versions up to V 4.3 or older


selected removable memory
is not plugged onto the PI board.

Please note!
This message may be shown
when the machine is first switched on
(put into service) and/or on
first use of a PMS card
because the A or B memories
or the PMS card has not been
initialized by a deleting procedure.

- 51 -

Plug the removable memory


into A or B slot on PI board
Replace removable memory, replace
PI board.

Accompanying material for technical training course

Mon gb 01 04.04.2005

DISPLAY

CAUSE

REMEDY

Mechanical lock
unlocked

This message indicates that


home position of machine (knife in
top dead center or machine just
turned on) the mechanical lock
(or the safety rocker switch) for the
knife bar is not in the
safety position.

Check if knife is in TDC,


wind the knife up, if necessary.
Turn machine off and turn the knife
manually to its top dead center
by turning the flywheel.
PLEASE NOTE!
Observe safety information.
Check smooth operation of mechanical lock
or safety rocker switch).
Check magnet Y.SB, check switch B.SBE,
Check plugs 44 and CUM.9 ,
replace SK board. ( Rel. K3 of MHY )

Mechanical lock
locked

Before the cut is started the mechanical


lock (or safety rocker switch) does not
Reach proximity switch B.SBA or not
in a timely manner,
or leaves the B.SBA proximity switch
during the cutting procedure.

Check smooth operation of mechanical lock


or safety rocker switch).
Check magnet Y.SB, check switch B. SBA,
Check plugs 44 and CUM. Replace SK
board

Mechanical lock
monitoring
defective

The mechanical lock (or safety


rocker switch) is in an
undefined state of malfunction. Both
proximity switches B.SBE and B.SBA
signalize simultaneously the positions
knife bar released and knife bar
locked.

Check smooth operation of mechanical lock


or safety rocker switch).
Check magnet Y.SB, check switches B.SBE
and B.SBA . Check plugs 44 and CUM 9
Replace SK board

non-return valve
42 V error

On one activated non-return valve


Y 315 no voltage of + 42 V is supplied to
switching line of non-return valve

Verify voltage supply (measuring point


SK. P1 Nom. + 50 V to + 55 V) solenoid valve
315 ( ohms ) must be checked, plug CUM.6
and magnet. Replace SK board

SPV ERROR

Internal error message for


memory management of CP1 board

Switch machine off and on


Verify voltage supply
Replace CP 1 board

Static cutting
circuit error

No agreement between software


Remove any obstacles from the optical path
activation and safety control channel
of the LS and finish the cutting process.
of SK board. Verify voltage supply,
Replace SK board.
Sporadic occurrence of this message
does not necessarily indicate a malfunction
in any case. On V 5.1 and V 4.2 this
message occurs if an interrupted
cut is continued while the light barrier
is interrupted.

- 52 -

Accompanying material for technical training course

Mon gb 01 04.04.2005

DISPLAY
TXT - ERROR

PMS CARD
invalid

CAUSE

REMEDY

After turning the machine on


erroneous identification
of text Eprom on CP 1 board.

Replace CP 1 board

The PMS card plugged into the


control unit cannot be identified.

Use original PMS CARD


Check, if PMS CARD has been inserted
correctly replace PMS CARD

Observe
Counter for service has exceeded
maintenance interval 100,000.
Note

Reset the counter for service under


Survey of functions ( 7 ).

Inadmissible value
Note

During the programming an


inadmissible input
was detected (e.g. total cuts 0 ).

Verify programming

Overflow
Note

When using the calculating


function, an overflow of the
arithmetic memory was caused.

Target program
data error

While using the functions


COPY PROGRAMS,
COPY ONTO PMS CARD and
LOAD FROM PMS CARD
all the data from the
target program could not be read
PS board, replace PS board

Remedy up to V4.4;
Completely delete the relevant program
and input again, check battery of
removable memory, replace
removable memory, replace PI board
check voltage supply of
.
Remedy as of V5.0:
Completely delete the relevant program
and input again. When using
the memory areas A or B check battery of
CP 1 board, replace CP 1 board
Check voltage supply to
PS board, replace PS board
When using the PMS CARD,
check the PMS CARD, its battery,
PMS-Card slot, replace BTM,
replace KC

Additional function
inadmissible
Note

Inadmissible additional function


was called up.

- 53 -

Verify operation

Accompanying material for technical training course

Mon gb 01 04.04.2005

DISPLAY
Target memory not
readable

CAUSE

REMEDY

While using the


functions COPY PROGRAMS
COPY ONTO PMS CARD and
LOAD FROM PMS CARD no
data of the target memory
can be read.

- 54 -

Remedy up to V4.4:
Completely delete the relevant program
and input again. Check battery of
removable memory, replace
removable memory, replace P1 board
Check voltage supply of
PS board, replace PS board
Remedy as of V5.0:
Clear the relevant program completely and
input again. When using the A or B memory
area check battery of CP 1 board, replace
CP 1 board. Verify voltage supply to PS
board. When using the PMS - Card, check
the PMS Card, its battery, check the PMS
CARD slot, replace BTM, replace KC

Accompanying material for technical training course

Mon gb 01 04.04.2005

SERVICE INFORMATION
Since the I / O bus boards are switched in parallel (see block diagram, page 3) a defective board may
affect machine functions which are controlled by another board. By removing the boards one by one the
defective board can be localized.
1.

All machine functions except for the monitor display are possible without the Video (VID) plug-in
board.

2.

The functions of backgauge movement, display and control panel are possible without the cutting
circuit (SK) board plugged in. The message enable cut buttons is displayed on the screen.

3.

All the machine function except for the operating elements on the control panel are possible
without the assembly of Keyboard Computer (KC) and control unit (BTM).

4.

Self-test of the Keyboard Computer ( KC ) and control unit ( BTM ) assembly:


With the machine switched off, remove the plug-in connection of the X 500 serial interface from
the KC board. (see drawing on page 26)
Make a short-circuit bridge by plugging the test connector onto X 500.
The test plug is on the right side of plug X 500.
Switch the machine on.
Activate self-test by pressing the key S1 on the KC board.
The red LED Test okay V20 is lit when the self test of the Keyboard Computer has been
performed without errors.
When one of the keys is actuated or released or when the rotary switch is adjusted on board
BTM you hear an acoustic signal.
While a key is being actuated the LED V20 Test okay is out.
Turn the machine off and re-establish the X 500 connection.
Put test plug back to the position of rest.
The test plug does not affect the machine control system.

5.

When the machine is switched off with the backgauge brake electrically activated or the last
backgauge position stored no longer available, for instance because the battery on the CP1 board
has been replaced, the machine has to be moved to reference position after it has been switched
on.
Once the control voltage has been connected the monitor displays the prompt = go to reference
position = actuate hand wheel.

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When searching the reference position the control system determines the following
parameters:
End of table

(Distance between cutting line and rake when the rear table limit switch is
reached).

Slow down travel

(Distance between the switchover point from the high to the low backgauge
motor speed on one hand and reaching the low speed on the other hand).
The computer multiplies this distance by the factor of 1.5 in order to
compensate for fluctuations.

Brake afterrun

(Distance between the shut-off point of the brake lifting solenoid and the
backgauge at standstill).

Caution!

If the backgauge movement has been modified,- for instance by


- replacement or readjustment of the brake lifting solenoid
- replacement of the backgauge motor
- modification of the reference position
- replacement or readjustment of the spindle nuts
- readjustment of sledge guide
- change of position of the rear table limit switch
- replacement of the CP1 board,

the control system has to determine these parameters again while the machine is switched off with
the brake electrically activated. When the machine is turned on for searching the reference position,
activate the advance or return stroke.
6.

The front and rear limit stops of the backgauge movement is exclusively determined by the positions
of the table limit switches (hardware shutoff).
Adjust the limit switch in such a way that the smallest attainable cut size of the 92, 115 and 137
machines is 25 mm and on the 155 and 176 machines 35 mm.
The remaining limit switches must be set to ensure that the backgauge motor is switched off at
least 10 mm before the mechanical stop at the false clamp plate or at the end of the table is
reached.

7.

When the Service function has been selected from the Survey of functions, enter the code
number 8520 and confirm with the actual position key.
The screen displays: (as of program version V 2.0)
( 1 ) Machine data
( 2 ) Change machine data

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By input of the relevant number one of the two sub-menus is branched.


( 1 ) Machine data
Language presetting
Measuring unit presetting
Text - Eprom Version
Software Version
Brake afterrun
Slow down travel
End of table

EM ( C ) - Monitor V...
E. g.: German
E. g.: cm
V...
E. g.: 0.034 cm
E. g.: 2.154 cm
E. g.: 116.83 cm

( 2 ) Change machine data

EM ( C ) - Monitor V...

( 1 ) Accuracy allowance

(max. permissible tolerance in a positioning


procedure.The factory setting is 0.008 cm.
Possible values:
0.008 0.1 cm )

( 2 ) Total cut counter

E. g.: 88888888

( 3 ) Switch-off display correction

(if the max. admissible tolerance is not exceeded in


a positioning process the actual position display will
be rounded up or down.)

(3a) Switch-on display correction

(In this case the actual position display is not


rounded.)

( 4 ) Print service report


( 5 ) Input / output control

(shows the conditions of all essential input and


output signals of the control system.
Those signals which are not in their ground level
state are inverted. The features clamping, cut,
mechanical cutting-line indicator and manual
backgauge movement are available.)

( 6 ) Set reference position

(indication to support the setting of the reference


position)

( 7 ) Remark
8.

The functioning of the VID board and the screen can be verified by turning on the control voltage
without the CP1 board installed in the machine. The screen shows a test pattern which consists
of horizontal and vertical lines. This test pattern can be used for setting the image orientation,
height, width and linearity. The controllers for adjusting these parameters are located on the p.c.
board inside the screen housing. Please learn the positions of the controls from an adhesive label
on the tube bulb.

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9.

In order to retain the data when the control system is switched off the interchangeable memory
and the CP 1 board are provided with (3.5 V) batteries. These batteries should be replaced every
five years or when the battery voltage falls below 3 Volts.
The battery of the interchangeable memory should be changed with the memory
plugged in and the control voltage switched on, because the stored program data will
otherwise be lost. It is also possible to copy the program data into another memory before
replacing the battery.
The CLK board also carries a battery (2.4 V) which supplies the timer module when the
machine is switched off.

Secondary operation
The secondary operation makes the manual backgauge movement as well as the clamping and cutting
functions possible. The monitor continues to display all the data except for the actual position. Via the
keys on the control unit the individual menus can be selected (also the Service function).
There are two ways to get to the secondary operation
1.

When searching the reference position and no reference point is detected because of a defective
measuring system, a defective connecting cable for the measuring system or a defective PI plugin board, the system will automatically switch to secondary operation after the third attempt.
The program data image is shown, and instead of the actual position the text secondary
operation is displayed.

2.

If the Program Data button is pressed before or after searching the reference position, the
system switches instantly over to secondary operation.

Please note!
When the optional equipment optimized high-speed backgauge is available the
backgauge movement may be locked when the measuring system has suffered a failure. In this case,
no search of the reference position is possible. In this case, press the program data key to start the
secondary operation.

Deactivating automatic knife functions


(see IP 1 / 97)
POLAR EM / EMC Monitor machines
1.
2.
3.
4.

Plug the jumper ( MS ) onto the cutting circuit board ( SK ).


Install board SFM unless it is already installed.
Insert a jumper on the CU, from plug 57, pin 5 to pin 9.
Separate the strip conductor for the automatic knife ON key from the control unit.
Please remember to note down the changes on the customers circuit diagram

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Printer interface
All Monitor machines are prepared for connecting a printer. This connection is made by a serial
interface on the front side of the CP1 (X5) board.
Polar Machines are designed to work with Epson printers equipped with serial interfaces. The
necessary connecting cable is included in the toolbox of every Monitor machine upon delivery.
The following list shows the required devices:
Epson Matrix printer, such as: FX - 870
Serial interface:
Pull / push tractor
Sheet feeder

Purchase no. C094011


Purchase no. 8143
Purchase no. C806382
Purchase no. C800202

The above listed components can be purchased from Epson.


Printer cable

id. no. 020328 (Polar)

The Epson printers must be adjusted for program versions V 1.0, V 1.1, V 2.0, V 3.1(S), V 4.0(S) and
V 4.1(S), resp., in the following way:
Installation at EPSON FX 800 printer
1. Printer Board: Switch position (DIP - Switch)
DIP-Switch SW:

1 = PIN 1 = OFF
1 = PIN 2 = OFF
1 = PIN 3 = ON
1 = PIN 4 = OFF
1 = PIN 5 = ON
1 = PIN 6 = ON
1 = PIN 7 = ON
1 = PIN 8 = ON

DIP-Switch SW:

2 = PIN 1 = OFF
2 = PIN 2 = ON
2 = PIN 3 = ON
2 = PIN 4 = ON

Please remember to note down the changes on the customers circuit diagram

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2. Serial - Interface Board: switch positions


DIP - Switch SW:

DIP - Switch SW:

1 = Pin 1 = OFF
ON
1 = PIN 2 = ON
1 = PIN 3 = ON
1 = PIN 4 = ON
1 = PIN 5 = ON
1 = PIN 6 = OFF
1 = PIN 7 = OFF
1 = PIN 8 = OFF
2 = PIN 1 = ON
2 = PIN 2 = ON
2 = PIN 3 = OFF
2 = PIN 4 = OFF
2 = PIN 5 = OFF
2 = PIN 6 = OFF

Program Version V 2.0 - 0 V 3.1.0 (S)


Program Version V 4.0 (S) V 4.1 (S)
Program Version V 1.1 / V 1.0

3. Serial - Interface Board: Set jumpers


Jumper:

1 = OFF
2 = OFF
3 = OFF
4 = OFF
5 = ON
6 = OFF
8 A = ON
8 B = OFF
X = ON
F = OFF
C L = ON
R S = OFF

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Change of software versions according to IP

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Compatibility of the Video - CP 1 and KC boards

Explanation of graphic cards


1* = half size / 2 *= double size / 3* = monochrome / 4*= Mono Color / 5*= Graphics
CP 1 V 4.2 Replaces V 4.0 to V 4.1
Same software as V 5.0, but meant for machines without PMS Card
CP 1 V4.3

Replaces V 4.0 to V 4.2


Same software as V 6.0, but meant for machines without PMS Card

CP 1 V 4.4 Replaces V 4.0 to V 4.3


Same software as V 6.2, but meant for machines without PMS Card

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