EMC-Mon Op GB 06.02.04

Mon op GB 01 06.02.
2006
Technical Training
EMC
MONITOR
Optional Equipment
-1-
Accompanying material for technical training course
Mon op GB 01 06.02.2006
Table of Contents: EMC - Monitor OPTIONAL EQUIPMENT
Page
Special function (SFM)............................................................................................................... 3
SFM board................................................................................................................................ 4
Pin assignment of special functions............................................................................................. 5
Arrangement of limit switches and valves on Autotrim.................................................................... 6
Optional Autotrim 80.................................................................................................................. 7
Pneumatic diagram of Autotrim.................................................................................................... 8
Autotrim Wiring Diagram........................................................................................................... 9
Manual lowering of front table (up to V 2.0) ................................................................................. 10
Manual lowering of front table (as of V 3.1) ................................................................................. 11
Autotrim parts list..................................................................................................................... 12
Special Hydraulic System (SHM)............................................................................................... 14
SHM board.............................................................................................................................. 15
Retractable side gauges on EM / EMC Monitor machines............................................................ 16
New plug-in board Special Hydraulic System (SHM).................................................................. 17
Backgauge Lock on EM / EMC Monitor machines.................................................................... 18
Circuit diagram of special hydraulic system Monitor..................................................................... 19
Special hydraulic system parts list............................................................................................. 20
Swivel / tilting backgauge / Fixomat (DNF) (SER)........................................................................ 22
DNF board............................................................................................................................... 23
Basic mechanical adjustment of swivel - tilting backgauge............................................................24
Adjustment of DNF board for swivel backgauge............................................................................25
Adjustment of DNF board for tilting backgauge............................................................................ 26
DNF block diagram................................................................................................................... 27
DNFparts list............................................................................................................................28
Servo control (optimized high-speed backgauge) .........................................................................29
Mains connection and block diagram of Servo control...................................................................30
Connections at ESR..................................................................................................................32
SERVO board.......................................................................................................................... 33
Setting instructions for servo board and servo amplifier................................................................. 34
Service information for servo drive unit......................................................................................... 36
Automatic clamping pressure regulation (PDR)............................................................................ 51
P1 Control unit for automatic clamping pressure regulation........................................................... 53
Functional principle of automatic clamping pressure regulation...................................................... 54
PDR setting instructions............................................................................................................55
Program (V2.0) for automatic clamping pressure regulation........................................................... 56
PDR plug-in board.................................................................................................................... 57
P1 Oil Cycle with proportional pressure regulating valve............................................................. 58
PDR connecting plan............................................................................................................... 59
-2-
Mon op GB 01 06.02.2006
Special function (SFM)

The special functions board (SFM) serves to control the Autotrim table. In connection with the CP1 board
the program cycle provides an automatic activation of the solenoid valves for the pneumatic cylinder of the
front table.
On machines without Autotrim facility, this function must be turned off via switch S1 on the SFM board.
The board carries also eight relays which are energized for 0.5 seconds, each, when the external special
functions 1 - 8 are executed. The potential free contacts of these relays allow to synchronize the peripheral
equipments and the cutting sequence.
The maximum tolerable load for the contacts is 10 watts, 48 V.
Various inputs and outputs of the board allow for an adjustment of the control system to non-standard
special versions.
LED
V20
V1
V2
V3
V4
V5
V6
V7
V8
V9
P10
P11
V12
Color
yellow
red
red
red
red
red
red
red
red
red
red
red
red
Meaning
AT - LS monitoring
Autotrim table CLOSE
Autotrim table OPEN
cut
Automatic backgauge ON
ext. special function No. 8
No. 7
No. 6
No. 5
No. 4
No. 3
Autotrim table LIFT
No. 2
Autotrim table LOWER No. 1
Ground state
OFF
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
The special functions 1 -4 are carried out before the backgauge goes to the next position. The
special functions 5 - 8 are performed when the size has been reached.
-3-
Mon op GB 01 06.02.2006
Plug-in board SFM
-4-
Mon op GB 01 06.02.2006
Pin assignment of special functions
-5-
Mon op GB 01 06.02.2006
Arrangement of limit switches and valves on Autotrim
S 363 limit switch for bypassing the Autotrim light barrier

S 364 limit switch Autotrim table closed
S 365 limit switch Autotrim table open
Y 366 valve = table closed =

Y 367 valve = table open =
Y 389 valve = sweeper ON =
Y 390 valve = lower table =
-6-
Mon op GB 01 06.02.2006
Optional Autotrim 80
This optional equipment allows to handle waste cuts up to a max. 80 mm.
In order to make this function possible, the mechanical construction of the Autotrim table must be widely
reworked. The extended travel of the table, the blowing air device for removing cutting waste from the knife
bar (stripper flap is dropped) and the movable right-hand side gauge have caused modifications to the
pneumatic system and electrical control.
The following components of the electrical control unit are required for Autotrim 80:
1. New SFM board id. no. 020172 ( replaces obsolete version 020171 )
2. Suitable as of software versions V 6.1 - 0 V 5.3 - 0 V 4.4 - 0
The new SFM plug-in board ( 020172 ) can be used for all Autotrim machines. For this purpose, the board
has DIP switches which allow the user to select between 25 mm and 80 mm for the waste cut.
Switch position S 2 / 5
Switch position S 2 / 5
= OFF standard Autotrim ( 25 mm waste cut )

= ON = Autotrim 80
( 80 mm waste cut )
The hardware of the new SFM board has been

changed in the following way: when the opening
process of the table was interrupted, and the table
is then closed, both solenoid valves are briefly
activated in order to fill the cylinders. This enables
the Autotrim table to be started slowly and without
jerks. The time period for activating the solenoid
valves can be set on the board. Any unassigned
inputs which were only available on the board,
have been supplied to a 9-pin SUB D plug. The
software modification of the CP1 board affects
also the block program. Once Autotrim 80 is
detected, any waste cut that may have been
generated is set to 80 mm.
New SFM, see IP 1 / 93
-7-
Mon op GB 01 06.02.2006
Pneumatic diagram of Autotrim
-8-
Mon op GB 01 06.02.2006
Autotrim Wiring Diagram
-9-
Mon op GB 01 06.02.2006
Autotrim: Manual lowering of front table (up to V 2.0)
- 10 -
Mon op GB 01 06.02.2006
Autotrim: Programmable lowering of front table (from V 3.1)
- 11 -
Mon op GB 01 06.02.2006
Autotrim Parts List ( up to V 2.0 )

Component
Position
Function
M 371
N 380
Q 386
S 361
S 362
S 363
S 364
S 365
S 368
S 384
S 385
Table
Frame
Table
Frame
Frame
Table
Table
Table
Table
Tiltable table
Tiltable table
Compressor motor for suction and blown air

Amplifier for light barrier, Autotrim
Overload switch for compressor
Button: Autotrim ( open ) in TR ( pushbutton board right )
Button: Autotrim ( close ) in TR ( pushbutton board right )
Limit switch Autotrim (close)
Limit switch Autotrim (open)
Changeover switch suction air blown air
Tilt table limit switch left
Tilt table limit switch right
S 386
S 388
SFM
SER
V 361
V 383
V 381
V 382
Y 94a
Y 366
Y 367
Y 370
Y 389
Gearbox
Table
CU
Switching board
Frame
Frame
Frame
Frame
Table
Table
Table
Table
Table
Control switch for sweeper

Button for sweeper ON OFF
Plug-in board: Special function - Monitor
special electrical system carrying the relay unit
LED table ( open ) in TR
Flashing diode for light barrier Autotrim
Transmitter for light barrier Autotrim
Receiver for light barrier Autotrim
Solenoid valve air supply ON / OFF
Solenoid valve Autotrim (close)
Solenoid valve Autotrim (open)
Solenoid valve suction air
Solenoid valve sweeper
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Mon op GB 01 06.02.2006
Autotrim Parts List ( from V 3.1 )
Component
Position
Function
K1
K2
K3
M 371
N 380
Q 386
S 361
S 362
S 363
S 364
TR
TR
TR
Table
Frame
Table
TR
TR
Table
Table
Relay Lift the front table

Relay Lower the front table
Relay Change-over blown air / suction air
Compressor motor for blown air and suction air
Overload switch for compressor
Button Autotrim open
Button Autotrim close
Limit switch Autotrim (close)
S 365
S 384
S 385
S 386
S 388
S 400
S 401
SFM
SER
TR
V2
V3
V 381
V 382
Y 94a
Y 366
Y 367
Y 370
Y 389
Y 390
Table
Tiltable table
Tiltable table
Gearbox
Table
TR
TR
CU
Switching board
Light barrier
TR
TR
Frame
Frame
Table
Table
Table
Table
Table
Table
Limit switch Autotrim (open)

Tilt table limit switch left
Tilt table limit switch right
Control switch for sweeper ON OFF
Button for sweeper ON OFF
Button Autotrim Lift the front table
Button Autotrim Lower the front table
Plug-in board: Special function - Monitor
special electrical system carrying the relay unit
Pushbutton plate, right-hand
Flashing diode for light barrier Autotrim
LED Autotrim open
Transmitter for light barrier Autotrim
Receiver for light barrier Autotrim
Solenoid valve air supply ON / OFF
Solenoid valve Autotrim (close)
Solenoid valve Autotrim (open)
Solenoid valve Change-over blown air - suction air
Solenoid valve sweeper
Solenoid valve Lower the front table
- 13 -
Mon op GB 01 06.02.2006
Special Hydraulic System (SHM)
The hydraulic valves for the special equipment for
- Stack lifts
- Retractable side gauges
- Backgauge lock
are activated from the special hydraulic system board. The logic for interlocking the output
signals is located on this board.
In order to activate the functions retractable side gauge and backgauge lock, the switches S1 and/or S2
must be turned to 1.
LED
Color
V8
V9
P10
P11
V12
V13
V14
V15
green
green
red
red
red
red
red
red
V16
red
V17
V18
red
red
+24 V
+12 V
Valve lift left-hand side Y 160
Hy switch Y 330
Valve lift right-hand side Y 158
Valve VL left-hand side Y 155a
Valve VL right-hand side Y 155b
Valve - backgauge lock
fixed Y 331
Valve - backgauge lock
clear Y 391
Spare
Spare
Meaning Ground state
- 14 -
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
Mon op GB 01 06.02.2006
Special Hydraulic System (SHM) Plug-in Board
VL = retractable side gauge
- 15 -
Mon op GB 01 06.02.2006
Retractable side gauges on EM / EMC Monitor machines
In the Monitor machine range, the 176 model was the first to introduce a new design of the hydraulically
retractable side gauges. Both directions of motion (up / down) are now controlled hydraulically. The relevant
limit positions are scanned via limit switches. On this version, the hydraulic pressure is turned off when the
gauges are lowered. Besides the mechanical and hydraulic modifications this new model requires a new
special hydraulics plug-in board.
The new board SHM 020182 replaces the previous version with id. no. 020181.
Before using this board with the older VL version, the switches and jumpers on the board need to be set
correctly.
There are three different variants:
1. Machines 115 to 155 ( Programs V 1.0 - V 6.0 )
Version with unidirectional hydraulically controlled VL cylinder. Return motion (VL up) by spring power.
The VL is retained in its bottom position by a constantly activated special hydraulic system.
When employing the new SHM board ( 020182 ) the following setting needs to be made:
1. Switch S 1
2. Switch S 2
3. Switch S 3
4. Switch S 4
5. Jumper JP 1
6. Jumper JP 2
7. Jumper JP 3
ON = VL available
ON = backgauge lock ON
ON = old VL version
ON = Cut optimization (must be turned on)
ON
ON
ON ( Pin 1+2 )
2. 176 Machines
VL control in both directions through hydraulic system (twin cylinder).
1. Switch S 1
2. Switch S 2
3. Switch S 3
4. Switch S 4
5. Jumper JP 1
6. Jumper JP 2
7. Jumper JP 3
ON = VL available
ON = backgauge lock ON (176 = OFF)
ON = old VL version
ON = Cut optimization (must be turned on)
OFF
OFF
ON ( Pins 2+3 )
3. Machines 115 to 155 ( retrofit kit with program V 6.1 )

Version with unidirectional hydraulically controlled VL cylinder. Return motion (VL up) by spring power. By
converting the hydraulic / electrical system, the VL can also be retained in its bottom position without any
hydraulic pressure. This prevents excessive heating of the hydraulic system. The setting of switches and
jumpers on the SHM board is the same as on the 176 MON machine.
- 16 -
Mon op GB 01 06.02.2006
Switches and jumper positions on the new SHM board
old VL
with recovery spring
The function of the key vor > lower both VL <

in the left-hand light barrier housing, can be
preselected by removing or inserting the
diode V 7 on the new SHM board. If the
diode is available, both VL are activated by
pressing the key lower both VL. If there is
no diode, only the right-hand VL will be
activated. The operation of the left-hand VL
remains unchanged.
see IP 1 / 93
VL neu
Mit doppel Zylinder
- 17 -
Mon op GB 01 06.02.2006
Backgauge Lock on EM / EMC Monitor machines

Description of functions:
The following solenoid valves are required for the backgauge lock function:
Y330 change-over valve (switch)
Y331 needle valve tap (clamping ON)
Y391 needle valve tap (clamping OFF)
On all the machines equipped with backgauge lock this function must be turned on with switch S 2 on the
SHM board. The functioning of individual valves is indicated by LEDs on the SHM board. (see SHM board).
When the machine is turned on, no solenoid valve of the backgauge lock is activated, but through a spring
storage element which is integrated into the backgauge lock control unit, the backgauge lock remains
activated even when the machine is switched off. With the backgauge at rest, the spring storage element
also ensures that the pressure in the hydraulic circuit of the backgauge lock will be maintained even when
the solenoid valves Y 330 and Y 331 are no longer energized.
With a volume of approx. 3 cm the spring storage element is sufficient to compensate any arising pressure
loss.
By activating the motor brake of the backgauge drive motor, the solenoid valve Y 391 is briefly turned on
and provides a direct connection with the hydraulic tank. The oil contained in the backgauge lock control
circuit flows off and the backgauge lock is relieved.
When the backgauge stops, simultaneously with the shutoff of the motor brake the change-over valve Y
330 and the needle valve tap Y 331 are briefly turned on by the CP 1 computer via the SHM board. In this
way the oil circuit of the special hydraulic system is connected with pump P2 through the changeover
valve, while the needle valve tap opens the line to the clamping cylinder at the sledge.
The backgauge lock function is automatically carried out by CP1 provided that switch S 2 on the SHM
board is set to 1.
If the backgauge lock function is turned off by switch S 2 on the SHM board, Y391 will be shortly activated
to relieve the backgauge lock.
- 18 -
Mon op GB 01 06.02.2006
Circuit diagram of special hydraulic system
- 19 -
Mon op GB 01 06.02.2006
Parts list no. 1 - Special hydraulic system

Component
CP 1
CU
LG
PS
SHM
TL
TR
S 156a
S 156b
S 156c
S 161a
S 161b
S 162a
S 162b
S 171
S 173
SHM. K1
SHM. K2
SHM. K3
SHM. K4
SHM. -K5
SHM. K6
SHM. K7
SHM. K8
SHM. K9
SHM. K10
SHM. K11
SHM. S1
SHM. S2
SHM. V8
SHM. V9
SHM. P10
SHM. P11
SHM. V12
SHM. V13
SHM. V14
SHM. V15
SHM. V16
SHM. V17
SHM. V18
SHM. V19
SHM. V20
Position
CU
Frame
CU
CU
CU
Frame
Frame
TL
TL
TL
TR
TR
TL
TL
Lift
Lift
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
SHM
Function
Plug-in board: Central Processor
Control unit motherboard
Air cup distributor board
Plug-in board: Power Supply + 5V / 12V / 24 V =
Plug-in board: Special hydraulic system
Pushbutton board left-hand side
Pushbutton plate right-hand side
Key: Retractable side gauge, left-hand down
Key: Retractable side gauge, left and right-hand down
Key: Retractable side gauge, upper position
Key: Stack lift, right-hand side, up
Key: Stack lift, right-hand side, down
Key: Stack lift, left-hand side, up
Key: Stack lift, left-hand side, down
Air cup: left-hand limit switch
Air cup: right-hand limit switch
Relay: solenoid valve lift left-hand side up
Relay: solenoid valve backgauge lock fixed
Relay: solenoid valve - spare
Relay: solenoid valve - retractable side gauge, right-hand
Relay: Spare
Relay: solenoid valve - retractable side gauge, left-hand
Relay: Spare
Relay: solenoid valve lift right-hand side up
Relay: Spare
Relay: change-over valve ON
Relay: solenoid valve backgauge lock relieved
Changeover switch: Retractable gauge available / not available
Changeover switch: backgauge lock activated / not activated
Indication: Control voltage +12 V d.c.
Indication: Control voltage +24V d.c.
Indication: solenoid valve lift left-hand side ON
Indication: change-over valve (switch) ON
Indication: Lift, right-hand side ON
Indication: Retractable side gauge, left-hand ON
Indication: Retractable side gauge, right-hand ON
Indication: backgauge lock fixed
Indication: backgauge lock relieved
Indication: Spare
Indication: Spare
Indication: Spare
Indication: Spare
- 20 -
Mon op GB 01 06.02.2006
Parts list no. 1 - Special hydraulic system

Component
TL. V3
TL. V5
Y 155a
Y 155b
Y 158
Y 160
Y 170
Y 172
Y 330
Y 331
Y 391
Position
TL
TL
Frame
Frame
Frame
Frame
Blower
Blower
Frame
Frame
Frame
Function
Indication: Retractable side gauge, left-hand lowered
Indication: Retractable side gauge, both lowered
Solenoid valve: Retractable side gauge, left-hand down
Solenoid valve: Retractable side gauge, right-hand down
Solenoid valve: Stack lift, right-hand side, up
Solenoid valve: Stack lift, left-hand side, up
Solenoid valve: air for air cap left-hand side
Solenoid valve: air for air cap right-hand side
change-over valve (switch)
Solenoid valve: backgauge lock fixed
Solenoid valve: backgauge lock relieved
- 21 -
Mon op GB 01 06.02.2006
Swivel / tilting backgauge / Fixomat (DNF) (SER)

The DNF board controls the d. c. motors of the Fixomat front and side lay marks. The supply voltage of the
motors is derived from the secondary voltage 0 - 15 - 30 Va.c. of the control transformer.
The three-phase motors for the swivel and tilting backgauge are activated through the relays K 353 - K 354
- K 355 - K 356 on the SER board.
Potentiometers acknowledge the current status of the backgauge setting. The analog voltages of the
potentiometers are digitized on board DNF via an analog-digital converter and then signaled to the central
processor (CP 1).
Depending on the machine equipment, the different functions need to be activated by the switches
on the DNF board.
S 1 for tilting backgauge
S 2 for swivel backgauge
S 3 for Fixomat
LED
V1
Color
yellow
Meaning
Tilting backgauge activated
Ground state
on / off
V2
yellow
Swivel backgauge 0 position
S 352
on
V3
yellow
Tilting backgauge 0 position
S 351
on
V4
red
V5
red
V6
red
) indication for the position
V7
red
) Swivel / tilting backgauge
V8
red
V9
red
V 10
yellow
Fixomat side lay mark
S 341
on
resting position
V 11
yellow
Fixomat side lay mark activated
S 342
off
V 12
yellow
Fixomat front lay mark
S 343
on
S 344
off
resting position
V 13
yellow
Fixomat side lay mark activated
V 14
red
Fixomat side lay mark, swivel forward
off
V 15
red
Fixomat swivel back the side lay mark
off
V 16
red
Fixomat front lay mark swivel forward
off
V 17
red
Fixomat swivel back the side lay mark
off
- 22 -
Mon op GB 01 06.02.2006
DNF plug-in board
- 23 -
Mon op GB 01 06.02.2006
Basic mechanical adjustment

= swivel backgauge =
Basic mechanical adjustment

= tilting backgauge =
- 24 -
Mon op GB 01 06.02.2006
Adjustment of board DNF for swivel and tilting backgauges

Swivel backgauge setting:
Select swivel backgauge!
1.) Move swivel backgauge mechanically to zero position ( see page 24 ).
2.) Adjust potentiometer RD in such a way that a voltage of 2.5 V +/- 0.05 V can be measured
between the measuring points MP1 and MP5.
3.) Use potentiometer R41 to set the voltage between the measuring points MP1 and MP4 to 0 V +/- 2
mV.
4.) Turn the center switching cam at the backgauge, until switch S352 is actuated.
LED V2 is on.
5.) Set the swivel backgauge to maximum mechanical displacement, using the controls - swivel
backgauge right-hand side forward.
(Before doing so, attach the dial gauge to the front edge of the rake. )
Swivel backgauge, right-hand
(displacement at outside rake)
POLAR 115 1.3 mm
POLAR 137 1.5 mm
POLAR 155 1.7 mm
6.) Turn the switching cam, until delimiting switch S348 is actuated.
7.) Use potentiometer R39 (DNF) to set the following LED indications:
V4
V5
V6
V7
V8
V9
OFF
OFF
ON
ON
OFF
OFF
This setting is equivalent with the

value 20 in the indication
with swivel backgauge right-hand side forward!
8.) Set the swivel backgauge to maximum mechanical displacement, using the controls - swivel
backgauge left-hand side forward. (Before doing so, attach the dial gauge to the front edge of the
rake. )
Swivel backgauge left-hand side
(displacement at outside rake)
POLAR 115 1.3 mm
POLAR 137 1.5 mm
POLAR 155 1.7 mm
After the setting is finished the monitor must display the following values for the final position:
swivel backgauge left + right-hand side = 20
- 25 -
Mon op GB 01 06.02.2006
Adjustment of board DNF for swivel and tilting backgauges

= Tilting backgauge setting =
Select tilting backgauge!
1.) Move tilting backgauge mechanically to zero position ( see page 24 ).
2.) Adjust potentiometer RN in such a way that a voltage of 2.9 V +/- 0.05 V can be measured between
the measuring points MP3 and MP5.
3.) Use potentiometer R44 to set the voltage between the measuring points MP3 and MP4 to 0 V +/- 2
mV.
4.) Turn the center switching cam at the backgauge, until switch S351 is actuated.
LED V3 is on.
5.) Set the tilting backgauge to maximum mechanical displacement, using the controls - tilting
backgauge backward.
(Before doing so, attach the dial gauge to the front edge of the rake. )
Tilting backgauge backward
( Displacement at upper edge of rake )
1.7 mm
1.7 mm
1.7 mm
7.) Use potentiometer R42 (DNF) to set the following LED indications:
V4
V5
V6
V7
V8
V9
OFF
OFF
ON
ON
OFF
OFF
This setting is equivalent with the

value 20 in the display only with
tilting backgauge backward!
8.) Set the tilting backgauge to maximum mechanical displacement, using the controls - tilting
backgauge forward. (Before doing so, attach the dial gauge to the front edge of the rake. )
Tilting backgauge forward
( Displacement at upper edge of rake )
0.5 mm
0.5 mm
0.5 mm
After the setting is finished the monitor must display the following values for the final position:
tilting backgauge backward = 20
- 26 -
tilting backgauge forward = 7
Mon op GB 01 06.02.2006
Detailed wiring diagram DNF
- 27 -
Mon op GB 01 06.02.2006
Parts List D N F
Component
BIM
BT-DNF
CP 1
CU
DNF
KC
PM
SER
S 341
S 342
M 345
S 343
S 344
M 346
Position
Frame
Frame
CU
Frame
Frame
Frame
Frame
Frame
Backgauge
Backgauge
Backgauge
Backgauge
Backgauge
Backgauge
Function
Control panel
Fixomat, swivel and tilting backgauge control unit
Swivel backgauge, tilting backgauge and Fixomat control unit
Keyboard Computer
Power supply unit
Special electrical system carrying the relay unit
Limit switch: retracted, side lay mark
Limit switch: extended, side lay mark
Motor: Fixomat for side lay mark
Limit switch: retracted, front lay mark
Limit switch: extended, front lay mark
Motor: Fixomat for front lay mark
Swivel backgauge
S 347
S 352
S 348
RD
M 357
K 353
K 354
Backgauge
Backgauge
Backgauge
Backgauge
Backgauge
SER
SER
Limit switch: backgauge, left-hand

Limit switch: 0 position
Limit switch: backgauge, right-hand
Potentiometer: Acknowledgement
Motor for swivel backgauge
Relay: backgauge, left-hand
Relay: backgauge, right-hand
Tilting backgauge
S 349
S 351
S 350
RN
M 358
K 355
K 356
V 10
V 11
V 12
V 13
V 14
V 15
V 16
V 17
Backgauge
Backgauge
Backgauge
Backgauge
Backgauge
SER
SER
FIX
FIX
FIX
FIX
FIX
FIX
FIX
FIX
Limit switch: Backgauge at front

Limit switch: 0 position
Limit switch: Backgauge at rear
Potentiometer: Acknowledgement
Motor for tilting backgauge
Relay: Backgauge at front
Relay: Backgauge at rear
Limit switch S 341 actuated (end position side lay mark, rear)
Limit switch S 342 actuated (end position side lay mark, front)
Limit switch S 343 actuated (end position front lay mark, rear)
Limit switch S 344 actuated (end position front lay mark, front)
Motor control M 345 (retract side lay mark)
Motor control M 345 (extend side lay mark)
Motor control M 346 (retract front lay mark)
Motor control M 346 (extend front lay mark)
- 28 -
Mon op GB 01 06.02.2006
Servo control
(optimized high-speed backgauge)
Mechanical system:
ball-bearing spindle
ball bushing
bearing housing (rear)
spindle bearing block (front)
backgauge sledge (bigger bore hole)
motor pinion
spindle pinion
toothed belt
motor console
*
Electrical system:
Servo motor 120Vd.c.
(Bautz)
power amplifier
(ESR)
Servo plug-in board (Servo)
CP 1 computer board(V... S)
rear limit switch
S 13a () *
front limit switch
S 7 / S 8 () *
In automatic operation the limit switches change over the backgauge speed to slow.
( = a quarter of the maximum speed )
On special versions (Transomat 3 BL, gripper transport system) the S121 switch is used instead of
limit switch S 13a.
Description of functions
Mechanical system:
The ball bearing spindle with ball bushing is set during the assembly in the factory. It requires no readjustment
even after a longer operation time.
the ball bearing spindle always has to be replaced completely, together with the ball bushing.
Never turn the ball bushing off the spindle, because all the balls would drop out of the bushing and the
bushing could not be used any longer.
A mounting sleeve is necessary for installing the ball bushing onto the spindle and also for dismantling it.
In dismantled condition, the spindle torque should be 1 Nm. In assembled condition a value of
2.5 Nm should not be exceeded.
Electrical system:
The ESR Servo power amplifier is mounted to the crosshead under the rear table.
The mains connection is made from the machine with a 5-core cable via adapter plug no. 100. The supply
voltage can be changed over in the power amplifier from 200 - 440 V three-phase.
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Mon op GB 01 06.02.2006
Power supply from control unit
The servo motor is connected with a shielded two-core cable from the power amplifiers terminals 1 and 2,
shielding terminal 3.
The tachometer generator is also connected by a shielded 2-core cable at the power amplifier, terminals
4 and 5, shielding terminal 3.
As on the machines without servo control, the motor brake is connected with a two-core cable, plug 104,
at the MCM.
Data transfer from the Servo board to the Servo power amplifier is performed with a four-core cable with 15pin plug.
Servo Control block diagram
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Mon op GB 01 06.02.2006
Explanations regarding the block diagram on page 30
(( 1* ) =Enable: Signal Motor ON.

For backgauge movement, the enable signal is issued from CP 1 via yP bus to PI.
PI
signals brake enabled and the K1 relay on PI turns on the K1 relay on the Servo board. Zero
signal is indicated on terminal 15 of the control unit and power amplifier is activated. Servo LED
V9 = brake enabled / V1 = motor ON.
( 2.) = Control signal: Control voltage for motor speed control. Depending on the machine direction
there is a voltage between 0 and + 10V d. c. or 0 and - 10V d. c. 0V with backgauge Stop. The
control signal is supplied from the CP 1 via the yP bus and the Servo board to the control unit
(ESR). Terminal 11
Through voltage control the motor speed is infinitely variable from V 0 to V max. The motor brake is
switched on when the CP 1 has the signal V 0. The brake is meant to lock the motor at standstill. The
V max. speed (approx. 31 cm./sec.) is reached after approx. 13.5 cm, and in automatic mode, only.
The regulation from V max. to V 0 requires also 13.5 cm. In the service display this value is indicated
as a slow down travel. The V max. speed is only obtained with distances of more than 27 cm. The
max. current of the control unit is set to 12 amps. If the current limit is set too low, the motor will not
reach its full speed. At V max. the current is about 5.5 amps.
The motor speed is determined with a tachometer generator. When the speedometer fails, the
backgauge will go to V max. manually and without control. Poor carbon brushes will cause uneven
operation!
Drift velocity. This velocity is only determined in a reference run. Once the rear table limit switch (S13)
has been reached, the backgauge stops its advance movement for approx. 2 3 sec. after about 15
cm. The power glide is measured and the backgauge moves forward to approx. 40 cm. The drift
depends on the offset adjustment on the Servo board as well as the zero point in the ESR amplifier.
Set the current limit. As of CP 1 version V 6.0 the error message No pulses from measuring system
is issued when the backgauge is locked. From this program version, the auxiliary operation must be
turned on before the current limit can be set.
When the carbon brushes of the tachometer generator are worn or soiled, the motor will not run
smoothly or it will approach the positions inaccurately.
Carbon brushes for motor :
Id. no. 227361 4 x
Carbon brushes for tachometer generator:

Id. no. 227362 2 x
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Mon op GB 01 06.02.2006
The ESR has the following connections:
Terminal 11 = orange
Terminal 13 = yellow
Terminal 14 = brown
Terminal 15 = red
Terminal 20 = all black-colored cores
up to max. + 10 V depending on direction of rotation

- 14 V
+ 14 V
Enable (relay K1 on Servo board)
0V
The table limit switches S 13a ( S121 ) and S 7 are connected to the Servo board by means of the 9pin plug.
The Servo power amplifier has three light-emitting diodes which indicate different operational
conditions.
Operation
Limit switch opened
Enabling actuated
Overload indication
x green
x yellow
(all voltages available)

during operation: OFF
x red
Beneath the LEDs there are five trimming potentiometers
(rotation top the right means)
current setting
feedback adjustment
I x R compensation
without tachometer generator)
Zero point adjustment
Speed setting
P4
P3
P8
(current is increased)
(motor runs more smoothly)
( stronger compensation, only used
P2
P1
( motor standstill )
(speed is increased)
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Mon op GB 01 06.02.2006
Servo plug-in board
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Mon op GB 01 06.02.2006
SERVO SETTING
! Move backgauge to center of table!
1. Zero balancing of Servo board in CUM module
The Servo board must be plugged onto an adapter. Make sure that the computer has preset a control
voltage of 0 V (automatic positioning must not be activated).
Connect voltmeter to measuring points MP 2 and J2 Pin 3.
Use potentiometer P1 to set the voltage to 0 V.
Switch the machine off and remove the adapter board.
2. Zero balancing of Servo power amplifier ESR

a) Jumper J2 on the Servo board in such a away that the Pins 2 and 3 are linked.
b) Connect terminals 15 and 20 on the power amplifier with a jumper
( enable ).
c) By-pass the S 18 switch of the manual precision adjustment at plug CUM 14, contacts 3 and 6,
( Motor brake must be activated ). Then, switch the machine on.
d) Adjust potentiometer P2 at the ESR ( zero point adjustment ) until servo motor is at a standstill (
see actual value on the monitor or measure the speedometer voltage).
Switch machine off .
e) Plug jumper J2 on Servo board in such a away that the Pins 1 and 2 are linked. Remove bridges
between terminals 15 and 20 as well as switch S18 at CUM 14.6 and CUM 14.3.
3. Setting the number of revolutions at the servo power amplifier (ESR)

With the tachometer the number of revolutions is measured direct at the end of the spindle (second
person necessary).
The potentiometer P1 ( speed ) is adjusted in such a way that the spindle runs 1800 rpm. in
automatic operation, and 900 rpm. in manual operation (use hand wheel).
The motor speed must not exceed 2800 rpm. (measured at the motor shaft).
4. Feedback setting procedure

The feedback is set at P3 ( feedback ) in the following way:
Turn the potentiometer P3 counterclockwise, until the servo motor runs audibly harsh.
Then turn the potentiometer P3 slowly clockwise, until the servo motor runs smoothly over the entire
speed range. Then check movement to position without display correction.
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Mon op GB 01 06.02.2006
5. Setting the power limit

The current setting at the servo power amplifier is carried out in the factory. It should only be readjusted
when the P4 potentiometer (current setting) has been misadjusted or the red LED lights up because of
an excessive load on the servomotor. The current can be set from 2 12 amps.
Lock the motor (best at the rear of the table). Switch measuring instrument into motor line. (direct
current up to 30 amps) Set current at P4 to max. 12 amps.
Note: From CP1 version V 6.0 the auxiliary operation must be activated before the current limit can be
set. Otherwise, when the backgauge is locked the error message No pulses from measuring
system would be issued.
After any new setting the machine must be initialized in a reference run, because the new
machine parameters on the CP4 board must be saved as machine data!
The servo board has six LEDs.

V1
= yellow
Enabling of servo control; in operation ON
V2
= red
not assigned
V3
= green
not assigned
V9
= yellow
Motor brake active
V 10 = yellow
table limit switch S 13a (S 121)
V 11 = yellow
table limit switch S 7
Technical Data:
Accuracy allowance
= 0.008 cm - 0.100 cm adjustable
Slow down travel
= approx. 13.000 cm
Brake afterrun
= 0 0.004 cm
Drift (as of CP 1 V 6.0)
= cm / sec. ( 0, if possible )
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Mon op GB 01 06.02.2006
SERVICE INFORMATION
Optimized high-speed backgauge (servo drive)
1. Servo boards
The following boards have been employed for servo machines by now
Id. no. 023184 used up to program version V 6.1/A-Z/O, incl.
Id. no. 029176 used from program version V 6.2 - 0
Id. no. 029216 used only with model EMC - G (full graphics)
Information regarding servo board id. no. 029176
This board helps to get a more distinct information from the error message No pulses from
measuring system.
There is a hint regarding a defective servo amplifier and backgauge motor. This distinction can only be
made provided that program version as of V 6.1 and the new set of cables ( id. no. 029346 and 029348
) are installed. On machines with 2-m table the cable set (id. no. 029346 and 029347) is indispensable.
2. CP 1 computer board
The following program statuses have been employed for servo machines so far:
CP 1 V 3.0 S
CP 1 V 3.1 S
CP 1 V 4.0 S
CP 1 V 4.1 S
CP 1 V 4.2 S
CP 1 V 4.3 S
CP 1 V 4.4
Id. no. 020153

Id. no. 020157
Id. no. 023804
Id. no. 023611
Id. no. 023612
Id. no. 023613
Id. no. 023774
CP 1 V 5.0 S
CP 1 V 5.1 S
CP 1 V 6.0 S
CP 1 V 6.1-0 a
CP 1 V 6.1-0 b
CP 1 V 6.1-0 c
CP 1 V 6.1-0 d
CP 1 V 6.1-0 e
CP 1 V 6.2-0
Id. no. 024340

Id. no. 024341
Id. no. 024850
Id. no.
Id. no.
Id. no.
Id. no.
Id. no.
Id. no. 024841
no longer available
no longer available
machines without PMS
keyboard computer id no. 020111
S identification is omitted, because program is

also designed for normal drive
machines with PMS
machines with PMS
S identification is omitted, because program is

also designed for normal drive replaces all programs
from V 6.1 / A - Z / 0
3. Cable harness: Servo board / servo amplifier

Old version, consisting of two cables with
New version, consisting of two cables with
{new version of cables for 2-m table with)
Id. no. 023173 and 023174

Id. no. 029346 and 029348
Id. no. 029346 and 029347
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Mon op GB 01 06.02.2006
4. Servo amplifier ESR

The following devices have been used by now:
a.) BN 6454. 0715
b.) BN 6454. 0890
c.) BN 6454. 0950
id. no. 227014

id. no. 227153
id. no. 227153
prim. Connection
prim. Connection
prim. Connection
3 x 380V
3 x 200V to 3 x 415V
3 x 200V to 3 x 440V
The following PI wiring was selected for the above mentioned units:
The wiring applies to the program versions V 3.0 S to V 5.1 S
1.
2.
r 37 = 52 k Ohm
c13 = 100 nF
d.) BN 6454. 1222
id. no. 228925
prim. Connection
3 x 200V to 3 x 440V
The following PI wiring was selected for the above mentioned units:
The wiring applies to the program version V 6.0 S
1.
2.
r 37 = 100 k Ohm
c13 = 33 nF
e.) BN 6454. 1439 id. no. 229229 prim. connection 3 x 200V to 3 x 440V
The following PI wiring was selected for the above mentioned unit:
The wiring applies to program versions as of V 6.1 - 0
1.
2.
r 37 = 110 k Ohm
c13 = 15 nF
The BN 6454.1439 device is equipped with a DIP switch which makes it easy to make the PI
adjustment when the device has to be replaced,
(see section on PI wiring)
Some of the devices designated as assembly 1222 and 1439 are designed short-circuit proof. You can
recognize this feature by a red-colored LED on the base plate of the amplifier. All those defective servo
amplifiers sent-in for repair which do not comply with the technical status of the BN 6454.1439 device
will be modified correspondingly. This means that all replaced devices which have been given the new
type number 1439 after their conversion, will provide the same configurations which the new devices
provide.
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Mon op GB 01 06.02.2006
5. PI wiring at servo amplifier ( PI = proportional / integral )

The setting for the relevant program status is made with switches S1 to S6. For the current delivery
status of the ESR device, please refer to the table.
LED 1 = operation
LED 2 = limit switch
LED 3 = overload
P 4 Potentiometer = current limit

P 3 Potentiometer = feedback
P 8 Potentiometer = I / R compensation
P 2 Potentiometer = zero point
P 1 Potentiometer = number of revolutions
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Mon op GB 01 06.02.2006
Examples for replacing a servo amplifier:

Machine 155 EMC - Monitor, S No: 5821123, Program status V 3.1 S
1. If the complete servo amplifier of the mentioned machine was defective and has to be replaced, only
the DIP switches for PI adjustment need to be fine-tuned . The switch package at amplifier 1439
becomes visible after the plug-in module at the ESR device has been removed. (see drawing on page
39) Before putting the machine into service, the motor should also be inspected. (Please observe the
maintenance of the motor).
2.
Same condition as in item 1,

but conversion to new software V 6.1 / A - Z / V 6.2-0
a. New servo amplifier BN 6454. 1439
b. New servoboard id. no. 029176
c. New cable harness id. no. 029346 + 029348 / 029347
d. New CP 1 board id. no. 024841 (V 6.2 - 0)
e. New keyboard computer id no. 023832
These service parts are required for the complete conversion. After the parts have been assembled, the
servo drive unit must be re-calibrated
(see setting instructions for servo drive unit)
Servo amplifier with optional leakage protection equipment

This optional equipment has been integrated into new devices from the model BN 6454.1222 onwards. It
can be recognized from the red LED on the amplifier base plate. In normal operation the LED is off.
When the LED lights up, the motor and supply line must be checked for accidental ground.
Plug-in module BN 37.1439
Output stages and controller board can be ordered under

id. no. 229367 from our spare parts department. In case
of a defect in an output stage, you always have to replace
both modules.
The assembly, id. no. 229367 is suitable for all the
servo amplifiers delivered so far.
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Mon op GB 01 06.02.2006
block diagram of servo drive unit

forward movement of backgauge via hand
wheel (button S 10)
1. input signal to Pl board (LED V23)
2. information supplied via uP bus to CP 1
3. CP 1 controls PI board via uP bus
a: brake Y17 (LED V33)
b: K1 on Pl (+24V via n/o contact LED V9)
4. CP 1 controls servo board via uP bus
a: K1 on servo board (NC contact),
=enabling of servo amplifier=
b: control signal for ESR device (approx. 4.8Vd.
c.)
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Mon op GB 01 06.02.2006
Wiring diagram SERVO drive unit
Control signal:
Control voltage for motor speed control. Depending on the
direction of rotation and number of revolutions there is a
voltage between 0 and + or - 10V d. c., respectively. The
control signal is supplied from the CP 1 through the yP bus
via the Servo board to the control unit (ESR) terminal 11.
Enable:
Control signal MOTOR ON. For backgauge movement, the
enable signal is issued from CP 1 via yP bus to board PI. The
PI board responds with the signal brake Y17 electrically
activated and simultaneously turns on the K1 relay on the
servo board with its relay K1. Zero signal is indicated on terminal
15 of the control unit and the power amplifier is activated. Servo
LED : V 9 ON = brake electrically activated / V1 ON = Motor on.
Acknowledgement:
Voltage level for CP 1 board for information about current motor speed. Depending on the number of
revolutions and direction of rotation there is a voltage between 0 and + or 14 V, respectively.
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Mon op GB 01 06.02.2006
Problem solving for machines with servo drive

Description of fault:
Zero point and drift cannot be adjusted correctly, or zero point or drift are not
stable while machine is in operation. Optimal value for zero point or drift is the
value >0.000<. with the resulting brake afterrun, which is also >0.000< with optimal
zero point or drift. Major variations between positive and negative values of drift
and brake afterrun also indicate that there must be an error in the adjustment.
admissible tolerances for
Drift:
Brake afterrun:
- 0.002 cm / sec to + 0.002 cm / sec

0.000cm to 0.004 cm maximum
Mechanical check:
Make sure that there is no mechanical stiffness throughout the backgauge travel. First, remove the toothed
belt from the spindle drive unit. Then slowly move the backgauge over the entire travel, using a torque
wrench. The max. admissible torque of 2.5 Nm must not be exceeded in this case. If the value is higher on
some points, please check the spindle guides, spindle and backgauge support for damages. The permissible
torque of the spindle alone (friction value spindle / nut) must not exceed 1 Nm. Moreover, after activation of
the motor brake an unimpeded rotation of the motor must be possible. This can be ensured by supplying
the brake coil directly with + 24 V d.c. If you notice a partial mechanical stiffness, please re-adjust the
brake or replace it.
Inspection of the motor control system:
As far as the servocontrol system is concerned, all the conversion steps should be taken to obtain the
status BN 6454.1439. This includes modifying the servo board and the amplifier cable. The following
measure should be performed:
1.
At the servo amplifier, please remove the bridge between the two terminals no. 12 and no. 20.
3.
The amplifier (ESR) has a jumper on the base plate which must be removed.
3.
Attach jumpers on the servo board.
4.
Modify connection cable of servo amplifier.

( please observe the drawings on pages 47 and 48 when carrying out the conversion)
If an additional error differentiation in the display shall be obtained, upgrade the program to
version V 6.1 0 or higher, and install the new cable harness which has two additional cores.
The new servo board id. no. 029176 is also required.
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Mon op GB 01 06.02.2006
Maintenance and repair of the servo motor with holding brake

The d. c. motor (made by Bautz) employed for driving the ball bearing spindle is composed of three
assemblies:
1. D. c. motor
1. D. c. motor
2. Tachometer generator
3. Holding brake
( carbon brushes 4 x id. no. 227361 )
The maximum voltage allowed to be supplied to the motor is 120V d. c.. The motor is supplied from the
ESR amplifier (terminals 1+2) via carbon brushes onto the collector. The max. adjusted voltage in this
example is approx. 112 V d.c. at a motor speed of approx. 2,800 rpm.
Important! The new carbon brushes are 17 mm long, and must never be shorter than 5 mm. Besides,
please make sure that the carbon brushes show an even contact pattern. Since the carbon brushes are
abrading and this powdered carbon collects in the motor and at the collector, the motor must be sent-in to
the manufacturer for maintenance work after the carbon brushes have been changed for the third time. The
motor cannot be cleaned on site, because the relevant cleaning devices (such as ultrasonic cleaning) are
not available. Furthermore, when the motor is at the manufacturers for maintenance purposes, the bearing
will be replaced and the collector re-worked. If the motor is not serviced, the deposit of carbon dust may
cause an accidental ground in the motor which results in malfunctions, or may even cause the servo
amplifier to be damaged in individual cases. Since the applications of the cutting machines vary greatly it
is not possible to indicate a definite period for the change of the carbon brushes. The motor should also be
inspected with regard to accidental ground, before new brushes are installed or if there are temporary
malfunctions of the servo drive. In that case disconnect the motor, check both lines for connection against
the motor housing with an ohmmeter; the collector should also been turned for this purpose).
2. Tachometer generator
( carbon brushes 2 x id. no. 227362 )
The tachometer generator is connected with the motor shaft and generates a voltage during the motor run,
which is supplied to the generator carbon brushes to the servo amplifier (terminals 4+5). This voltage
governed by the speed serves to control and stabilize the motor speed.
Important! The new carbon brushes are 9 mm long, and must never be shorter than 3 mm. Please
observe the contact pattern of the brushes also in this case. The generated d. c. voltage with max. speed
is approx. 38 V and can be measured at terminals 4 + 5 of the servo amplifier.
3. Holding brake
The servo control positions the backgauge precisely to the nominal position. Therefore the brake performs
only a holding function and is consequently smaller than the brake on a machine of the same type, but
with a normal drive system. The supply voltage is 24 V d.c., the brake air gap to be adjusted is 0.2 mm.
Since April 1990 Polar uses the brake made by Mayer. This brake is identical with the previously used
Lenze brake as far as the function is concerned, but the adjustment of the brake air gap is different. In the
past, some motors showed broken locking pins which caused the machines to break down. This is the
reason why we have been gluing the hub of the brake rotor additionally with Loctite 290 on the motor shaft
since one year ago. Now, should this particular type of locking pin ( DIN 7344 - 2,5 x 16 / id. no. 203490 )
break on older motors, the damage can be eliminated on site by gluing the hub and inserting a new pin.
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Mon op GB 01 06.02.2006
List of error messages for servo amplifier BN 6454.xxxx for optimized highspeed backgauge
Error:
Motor turns in neither direction of rotation
Cause no. 1:
Soldered fuse of surge limiter BN 1778. 715 is open.
Indication:
All LED in order, bimetal clip open
Error cause:
Mains transformer badly connected on the primary side ?

Excessive intermediate circuit voltage, caused by feedback of excessive braking
energy, for example by constant braking action of motor.
Surge limiter defective?
Elimination:
Re-establish soldered fuse connection by soldering. When doing so, make sure to
retain the spring force of the bimetal.
Check:
under normal operational conditions the red LED of the surge limiter p.c. board must be
OFF. It may only light up briefly when the motor is reversed.
Cause no. 2:
Short-to-ground responds
Indication:
Yellow LED (front panel) lights up; red LED on ground plate, or on older devices, red
LED on additional board HL 6454.1439 on the first slot of the motherboard lights up.
Error cause:
Accidental ground of one or both motor lines to the motor housing.

Caused by parting of cable in the motor line and resulting accidental ground to the
cable shield. By a worn-through motor cable. By dust of the brushes which caused
arcing to the motor housing.
Elimination:
In case of parting of cable install a new motor cable, check the motor, take measurement
with an ohmmeter or high-voltage tester between motor housing and one motor cable.
While doing so turn the motor shaft manually in order to detect a short over an entire
rotation of the motor. In case of accidental ground, replace the motor.
Important! For these measurements, the device must be turned off and the motor
disconnected. In order to reset the stored display messages, the yellow and red LED on
the device, turn the mains voltage off and re-connect it.
Check:
Under normal operational conditions the red LED on the motherboard or on supplementary
board HL 6454.1439 as well as the yellow LED on the front panel must be OFF.
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Mon op GB 01 06.02.2006
Cause no. 3:
Connection error or defective supply line
Indication:
Yellow LED (ESR front side) lights up.
Error cause:
- Enable input is open (terminal 15)

- Limit switch input is open (terminals 6 and 7)
- Line break at these inputs
- Short-to-ground, simultaneously the red LED lights up.
Elimination:
Measure the inputs (terminals 6, 7 and 15) to 0V (terminal 20) with voltmeter. The inputs
must be at 0V, in case of a malfunction the inputs go up to approx. +14V. Eliminate
accidental ground in motor line.
Cause no. 4:
Maladjustment or fault in motor circuit
Indication:
Red LED (ESR front side) lights up.
Error cause:
- Current limit set too low

- Motor locked
- Motor connection lines short-circuited one against the other
Elimination:
Check motor lines for short circuit. Switch ammeter into motor line. Current limit was
too low and must be redefined. To do so, lock the motor. The pulse current will flow for
some seconds. After that the devices switches back to constant current and the red
LED lights up. In this condition the current is adjusted to the nominal current of the
motor by means of the current limit potentiometer (front panel).
Check:
The ammeter should be monitored for some time throughout the intended operation of
the machine. In any case the mean current must be sufficiently below the adjusted
current limit.
Cause no. 5:
Interruption in motor circuit
Indication:
All LEDs (ESR front side) are in order
Error cause:
- Motor line interrupted

- Defective motor
- Defective output stage
Elimination:
- Measure nominal value input (terminals 11 and 12)

- Check carbon brushes of motor, use new ones, if necessary, or replace motor.
- In case of defective output stage, replace entire plug-in section.
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Mon op GB 01 06.02.2006
Cause no. 6:
Power supply error
Indication:
Green LED in ESR front panel does not light
Error cause:
- device is not switched on

- no mains voltage
- +/- 14V Reference voltage short-circuited
Elimination:
- Check back-up fuses of device

- Verify mains voltage at transformer of device (under left-hand side cover)
- Measure reference voltage + / - 14V ( terminals 13 and 14 ) to 0V ( terminal 20 )
Cause no. 7:
Activation error
Indication:
All LEDs ( ESR front side ) are in order. Motor is at a standstill at the moment or is
drifting slowly into one direction
Error cause:
No nominal value available
Elimination:
Measure nominal value input (terminal 11 compared to 12)
Error:
Motor runs without any control
Error cause:
- Tachometer generator of motor badly poled

- Tachometer line of motor broken
- Superimposed control circuit does not coincide with the direction of rotation of the
motor
- Servo board jumper plugged incorrectly
Elimination:
- Check connection of motor cable

- Measure tachometer voltage again (terminal 4 to 5)
- Interrupt any superimposed bearing control circuit (disconnect transmitter signals)
If the motor still does not run with speed control, exchange the connections of the
tachometer or the motor. If the direction of rotation is correct, the bearing control circuit,
if available, can be switched on again. If the motor runs without control, exchange the
transmitter signals of channel 1 and 2.
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Mon op GB 01 06.02.2006
Error:
Motor is running rough and uneven
Error cause:
- Switches of reversible PI wiring are maladjusted or not closed

- Potentiometer of feedback is badly adjusted (ESR front side)
Elimination:
- Verify switch position of PI wiring and set according to preset values

- Adjust potentiometer of feedback. Turn counter clockwise, until the motor runs
perceptibly rough, then turn slowly clockwise until the motor runs smoothly over the
complete speed range. Finally check brake afterrun and drift.
Error:
Zero point cannot be set
Error cause:
- Zero loop in the wiring.

- There is still one nominal value from the control system.
Elimination:
- Check wiring.
- Check activation of differential amplifier in the device (white colored wire on motherboard)
must be separated or removed).
Verify nominal value at input (terminals 11 and 12).
Check:
Disconnect nominal value from device and bridge terminals 11 and 12. Then adjust the
zero point. To do so, watch the motor shaft or measure the tachometer voltage.
- 47 -
Mon op GB 01 06.02.2006
Conversion of connecting cable at servo amplifier

old version
Connecting cable: 8 cores + shielding

id. no. 023173 + 023174
All colored cores are twisted in pairs with a black
core, each. All black cores are combined on
terminal 20.
new version
The orange core which is twisted in pairs with the

orange core is removed from terminal 20 and
supplied to terminal 12. In order to make this quite
sure, strip the insulation of the cable, if necessary.
das Kabel abisolieren.
- 48 -
Mon op GB 01 06.02.2006
Ramp adjustment of servo drive ( as of V 6.0 )

Type of fault:
With very smooth paper, error message position not reached and brake afterrun
exceeding 0,003 cm.
Possible cause: Mechanical stiffness of spindle or guiding mechanism.
Adjustment:
By changing the values for starting (1) and braking stage (2) the ramp of the servo
control system is modified.
Home setting by factory; start and braking stage 4
Inspection:
a. Switch off display correction in the Service image. Then select the display Adjust
positioning
b. Enter some measurement in function 4 (positioning).
c. Verify brake afterrun and drift values in the Service image.
Drift value must not exceed +/ 0.060cm/sec., optimal value: 0.000 cm /
sec.
If the value exceeds the maximum, a new servo adjustment (see service
documents) must be carried out.
d. Check maximum speed in Service image.
Nominal: 29.500cm/sec. - approx. 1800 r.p.m. at the spindle.
e. Turn indication correction on.
Adjusting the ramp:
Test:
Select starting (1) or braking stage (2) in the Set positioning image. Use the + or
key on the control unit to change the value.
a. (4) Select positioning

b. Enter nominal sizes and confirm by pressing = key two times
c. Backgauge goes to nominal size with re-adjusted starting and braking stages
d. If there have been no errors during the inspection, you can immediately start from
the data image. If there are problems, a new adjustment of the stages will be
necessary.
Press the C and = keys one after the other and select the new value.
Note:
Drift is the value which is set at the servo adjustment at pot P2 (on ESR unit) and
designated as zero point. Drift of 0.000 cm / sec.
= zero point has been perfectly set, servo motor is at a standstill after the positioning
process is terminated..
However, the indicated values of drifting and maximum speed only change
after a reference run has been performed!
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Mon op GB 01 06.02.2006
Parts list SERVO motor

CP 1
CU
CU
Frame
ESR
Table
SERVO control unit
G1
SERVO
Battery for clock (2.7 V d.c.)
J1
SERVO
Bridge: Battery ( G1 ) Voltage ON
J2
SERVO
Bridge: Nominal value zero for SERVO amplifier
K1
SERVO
relay for controller enabling
Table
SERVO motor
MCM
Frame
Backgauge motor control
PI
CU
Positioning Interface
S7
Table
Switches: Changeover of advance speed fast slow
S 13a
Table
Switches: Changeover of return stroke fast slow
Motor
Tachometer generator for SERVO motor
SERVO
CU
Plug-in board: SERVO control
Y17
Table
Brake lifting solenoid for backgauge brake motor
- 50 -
Mon op GB 01 06.02.2006
Automatic clamping pressure regulation (PDR)

The control for automatic clamping pressure regulation is divided into two blocks.
A. Hydraulic control unit:
Consisting of control block P1 with proportionally controlled pressure valve, one pressure sensor and two
micro filters.
B. Electronic control unit:
Consisting of:
1 PDR plug-in board
1 CUM module
8 light sensors
8 amplifiers for the light sensors
1 stepping switch 0 10 for pressure presetting
1 selector switch for sensors On/Off
Description of functions
The hydraulic P1 control unit has been newly conceived for automated clamping pressure regulation.
It is composed of:
1. proportional solenoid valve
2. pop valve
3. pressure sensor
The proportional solenoid valve is controlled to open or close at a varying degree by means of the current
via the PDR board. The pop valve is set at the factory to a value of 150 bars to protect the pump.
The valve seat in the proportional valve can be adjusted from the rear at the P1 control unit and has
also been factory set to 25 28 bars. This setting cannot be made when the unit is installed. ( From the
front, a correction within a range of + / - 3 bars can be made). Safety clamping pressure or clamping bar
speed are adjusted in the usual way. (Please, refer to the sticker on the frame pillar containing the hydraulic
system).
The pressure sensor is required for the data acquisition for the electronic system. Its temperature
compensation allows a max. pressure deviation of 1.5 bars in the range of 10 100C.
For automatic clamping pressure regulation the following connections are required at the CUM module
and the PDR plug-in board.
Sensor amplifier 1 - 4, plug no. 825 CUM unit
Sensor amplifier 5 -8, plug no. 826 CUM unit
Stepping switch clamping pressure selection and sensors ON/OFF.
Both units are accommodated in the control unit.
Prop. valve
plug no. 701 CUM unit

plug no. 702 CUM unit
Pressure sensor control block hydraulic system

Diode plug 6 - pin. PDR board
- 51 -
Mon op GB 01 06.02.2006
The clamping pressure selector switch is used for selecting the desired clamping pressure.
If the switch for the sensors is turned off, the clamping pressure regulation works manually, i. e. the
clamping pressure is adjusted according to the position of the preselection switch.
Clamping pressure selector switch set to 10:
on POLAR 115 / 137 = 4500 kp
on POLAR 155
= 5500 kp
on POLAR 176
= 6000 kp
- 52 -
Mon op GB 01 06.02.2006
P1 Control unit for automatic clamping pressure regulation
- 53 -
Mon op GB 01 06.02.2006
Functional principle of automatic clamping pressure regulation

When the switch for the sensors is turned on, the clamping pressure regulation works automatically, i. e.
the clamping pressure is regulated according to the number of sensors covered . Regardless of the material
alignment on the right or left-hand side in the machine: the more sensors are covered by material to be cut,
the higher will the clamping pressure be. The control unit has an internal table which differs for machine
types 92 to 176.
This tables includes all the pressure values (stepping switch 0 10) which are combined with all the
sensor conditions possible and the relevant current values for the proportional solenoid valve.
This special recording of all the values (teach-in program) is made at the factory for every single type of
machine, and will be retained even when the control system is turned off.
When the PDR board or the hydraulic block P1 is replaced, the setting must be made according to the
setting instructions, items A and B.
The 8 sensors integrated in the machine table supply one signal, each, to the control unit via 8 amplifiers
(1- 4 on the right, 5 8 on the left side).
At the factory the sensors are adjusted for dark paper. This can be seen from the red LEDs located at the
individual amplifiers. When the sensor is covered the LED at the relevant amplifier (24 V d.c.) lights up. If
no sensor is covered, all the LEDs are OFF (0V). If a readjustment is necessary, because an amplifier or
fiber optic cable has been replaced or when extremely dark cutting material has been used, the sensitivity
can be modified at the amplifier potentiometer (amplifiers are installed under the machine table) beneath
the red LED, with the machine switched on.
The sensitivity must not be increased so far that the amplifiers will be turned on by reflexions at the
pressure clamp or at the lower side of the false clamp plate when the clamp is in its upper resting position.
Cover the sensor with cutting material. Turn the potentiometer clockwise, until the red LED lights up.
Take away the cutting material. The LED must go out. If not, repeat this procedure.
When replacing a fiber optic cable, make sure that the cable will not be bent.
It must be laid with a radius of at least three times the thickness of the cable.
A cable is perfectly laid, when all the glass fibers on the amplifier side (unscrew cables from the amplifier)
are light when the sensor is not covered.
The fiber optic cable is screwed into the sensor bush with threaded sleeve - turn to the cover plate.
Then lock slightly.
When mounting the table into the frame, please proceed with utmost care to prevent any damages to the
light fiber cables under the table.
- 54 -
Mon op GB 01 06.02.2006
Instructions for setting the PDR board

Switch machine off . Wait, until main motor is at a standstill. Connect pressure sensor for pressure
gauge to the test tap at the P1 control unit. Switch the machine on.
A.
Zero calibration ( = circulation pressure ) press RESET button

1. Set mode selector (MOD) on the PDR plug-in board to 2.
2. Use the offset potentiometer to set the mode indication in such a way that the tens decade is
0 and the unit decade jumps from 0 to 1
(see illustration, PDR board).
B.
Adjustment amplification max. pressure V = max. / P = max.

1. Leave mode selector on the PDR plug-in board at 2.
2. Select special function clamping without cutting (D).
3. Press both cut buttons and set max. pressure with potentiometer P max.
POLAR 115, 137: 106 bar = 4500 daN
POLAR 155:
130 bar = 5500 daN
POLAR 176:
138 bar = 6000 daN
2. Press both cut buttons again, and use potentiometer V max to set the on-indicator pilot light on
the tens decade to F and the unit decade to a value between E and F ( junction).
Repeat procedures A and B. Set operating mode switch (MOD) to position 0.
C.
Activate teach-in program

1. Set operating mode switch to position 1.
2. Input cutting program, for example
100,000 cm + D ( Special function clamping without cutting )
ET 0.50 cm + D ( Special function clamping without cutting )
Adjust maximum retarding of cutting cycle with clamping time rotary switch.
Turn automatic knife on and trigger a cut.
3. Now all the table values (pressure values), from the minimum to the maximum pressure, stage 0 to
stage 10 are now learned one by one. The displays on the PDR board show the following values:
Unit decade
= clamping pressure stages 0 - A ( 0 10 )
Tens decade = number of active sensors ( 0 8 )
The training process is finished when the unit decade of 0 A and the tens decade of 0 8 have been run
through.
Once the teach-in program is terminated, set the operating switch to 0 position. The operating program
is activated and the display of the PDR board shows the number of activated sensors and the preselected
clamping pressure stage.
- 55 -
Mon op GB 01 06.02.2006
The PDR board is equipped with a battery-backed component with a 10 year life. Every time the machine
is turned on, the charging condition of the battery is checked.
If the battery is discharged so far that the data cannot be retained over the shut-off period of the machine,
the 2-digit indicator on the PDR board will flash.
The clamping pressure regulation function is maintained in this mode. But the clamping forces deviate
more from the preset values.
In case of an error in the internal control of the PDR board or the pressure sensor (on hydraulic control
block) an emergency operation will be switched on. The clamping force will then be set to approx. 80 % of
the maximum clamping force, irrespective of the position of the preselector switch.
On the display of board PDR - FF- is then flashing.
Program ( V 2.0 ) for automatic clamping pressure regulation

Since 1988 we use a new program version (V 2.0) for the optional clamping pressure regulation. The PDR
plug-in board, program version V 2.0 is suitable for all machines equipped with the optional automatic
clamping pressure regulation.
Version V 2.0 includes all the features of the preceding versions (fully-automatic) and the additional new
operating mode emergency operation.
With this operating mode, the pressure can be manually adjusted, if the sensors in the control block are
defective or the input stage of board PDR has failed.
Make the necessary setting for emergency operation in the following way:
1. Set the MOD switch from position 0 to 8
2. Press the reset key on the PDR board
3. Turn clamping pressure stepping switch on control unit to 10
4. Select special function D (=clamping without cutting =) and release the clamping process.
Use the P max. pot to set the maximum value, according to the type of machine.
115: 103 - 106 bar = approx. 4500 dN
137: 103 - 106 bar = approx. 4500 dN
155: 125 - 130 bar = approx. 5500 dN
176: 135 - 138 bar = approx. 6000 dN
5. For setting the minimum clamping pressure turn the stepping switch to 0, then turn the Size
switch to position 1 or F . Trigger a clamping action by pressing the cut buttons. With
position 1 the pressure is automatically and gradually increased, with F position, it is reduced.
As soon as the desired value has been reached, release the cut buttons and turn the Size
switch to 0 position.
The adjusted pressure values are saved and can be activated any time with the clamping pressure
stepping switch (0 10). These values remain stored even when the machine is turned off.
- 56 -
Mon op GB 01 06.02.2006
PDR board
- 57 -
Mon op GB 01 06.02.2006
P 1 Oil Cycle ( 1-channel ) with proportional pressure regulating valve
- 58 -
Mon op GB 01 06.02.2006
Connecting plan - automatic clamping pressure regulation
- 59 -

EMC-Mon Op GB 06.02.04

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Mon op GB 01 06.02.

Accompanying material for technical training course

Table of Contents: EMC - Monitor OPTIONAL EQUIPMENT

Accompanying material for technical training course

Special function (SFM)

Accompanying material for technical training course

Plug-in board SFM

Accompanying material for technical training course

Pin assignment of special functions

Accompanying material for technical training course

Arrangement of limit switches and valves on Autotrim

S 363 limit switch for bypassing the Autotrim light barrier

Y 366 valve = table closed =

Accompanying material for technical training course

= OFF standard Autotrim ( 25 mm waste cut )

The hardware of the new SFM board has been

Accompanying material for technical training course

Pneumatic diagram of Autotrim

Accompanying material for technical training course

Autotrim Wiring Diagram

Accompanying material for technical training course

Autotrim: Manual lowering of front table (up to V 2.0)

Accompanying material for technical training course

Autotrim: Programmable lowering of front table (from V 3.1)

Accompanying material for technical training course

Autotrim Parts List ( up to V 2.0 )

Compressor motor for suction and blown air

Control switch for sweeper

Accompanying material for technical training course

Autotrim Parts List ( from V 3.1 )

Relay Lift the front table

Limit switch Autotrim (open)

Accompanying material for technical training course

Special Hydraulic System (SHM)

The hydraulic valves for the special equipment for

Meaning Ground state

Accompanying material for technical training course

Special Hydraulic System (SHM) Plug-in Board

VL = retractable side gauge

Accompanying material for technical training course

Retractable side gauges on EM / EMC Monitor machines

3. Machines 115 to 155 ( retrofit kit with program V 6.1 )

Accompanying material for technical training course

Switches and jumper positions on the new SHM board

The function of the key vor > lower both VL <

Accompanying material for technical training course

Backgauge Lock on EM / EMC Monitor machines

Accompanying material for technical training course

Circuit diagram of special hydraulic system

Accompanying material for technical training course

Parts list no. 1 - Special hydraulic system

Accompanying material for technical training course

Parts list no. 1 - Special hydraulic system

Accompanying material for technical training course

Swivel / tilting backgauge / Fixomat (DNF) (SER)

S 2 for swivel backgauge

Swivel backgauge 0 position

Tilting backgauge 0 position

) indication for the position

) Swivel / tilting backgauge

Fixomat side lay mark

Fixomat side lay mark activated

Fixomat front lay mark