EMC-Mon_GB_04.04.2005

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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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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Control panel Monitor

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Arrangement of plug-in cards in the CU

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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

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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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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.

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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 customer’s 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.

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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

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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 customer’s 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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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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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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Mon gb 01 04.04.2005

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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Mon gb 01 04.04.2005

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 ìP 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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Mon gb 01 04.04.2005

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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Accompanying material for technical training course

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Accompanying material for technical training course

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Accompanying material for technical training course

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Accompanying material for technical training course

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Accompanying material for technical training course

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Accompanying material for technical training course

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Accompanying material for technical training course

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Accompanying material for technical training course

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Parts list no. 1 Title

Position

KC CRT CU SK CP1 PI VID PS ÜEB 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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Mon gb 01 04.04.2005

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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Mon gb 01 04.04.2005

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

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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

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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

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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

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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“).

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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.

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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.

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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.

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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.

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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

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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

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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.

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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.

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Plug the removable memory into „A“ or „B“ slot on PI board Replace removable memory, replace PI board.

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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.

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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.

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Verify operation

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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.

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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

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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 customer’s 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 customer’s 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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