emc-mon_op_gb_06.02.04

Mon op GB 01 06.02.2006

- 1 - Accompanying material for technical training course

Technical Training

EMCMONITOR

Optional Equipment

Mon op GB 01 06.02.2006


Table of Contents: EMC - Monitor OPTIONAL EQUIPMENT

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

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Special function (SFM)

The special functions board (SFM) serves to control the Autotrim table. In connection with the CP1 boardthe program cycle provides an automatic activation of the solenoid valves for the pneumatic cylinder of thefront 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 specialfunctions 1 - 8 are executed. The potential free contacts of these relays allow to synchronize the peripheralequipments 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-standardspecial versions.

LED Color Meaning Ground stateV20 yellow AT - LS monitoring OFFV1 red Autotrim table CLOSE ONV2 red Autotrim table OPEN OFFV3 red cut OFFV4 red Automatic backgauge ON OFFV5 red ext. special function No. 8 OFFV6 red No. 7 OFFV7 red No. 6 OFFV8 red No. 5 OFFV9 red No. 4 OFFP10 red No. 3 OFFP11 red Autotrim table LIFT No. 2 OFFV12 red Autotrim table LOWER No. 1 OFF

The special functions 1 -4 are carried out before the backgauge goes to the next position. Thespecial functions 5 - 8 are performed when the size has been reached.

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Plug-in board SFM

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Pin assignment of special functions

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Arrangement of limit switches and valves on Autotrim

S 363 limit switch for bypassing the Autotrim light barrierS 364 limit switch Autotrim table closedS 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 =

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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 widelyreworked. The extended travel of the table, the blowing air device for removing cutting waste from the knifebar (stripper flap is dropped) and the movable right-hand side gauge have caused modifications to thepneumatic 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 boardhas DIP switches which allow the user to select between 25 mm and 80 mm for the waste cut.

Switch position S 2 / 5 = OFF standard Autotrim ( 25 mm waste cut )Switch position S 2 / 5 = ON = Autotrim 80 ( 80 mm waste cut )

The hardware of the new SFM board has beenchanged in the following way: when the openingprocess of the table was interrupted, and the tableis then closed, both solenoid valves are brieflyactivated in order to fill the cylinders. This enablesthe Autotrim table to be started slowly and withoutjerks. The time period for activating the solenoidvalves can be set on the board. Any unassignedinputs which were only available on the board,have been supplied to a 9-pin SUB D plug. Thesoftware modification of the CP1 board affectsalso the block program. Once Autotrim 80 isdetected, any waste cut that may have beengenerated is set to 80 mm.

New SFM, see IP 1 / 93

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Pneumatic diagram of Autotrim

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Autotrim Wiring Diagram

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

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

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Autotrim Parts List ( up to V 2.0 )

Component Position Function

M 371 Table Compressor motor for suction and blown airN 380 Frame Amplifier for light barrier, AutotrimQ 386 Table Overload switch for compressorS 361 Frame Button: Autotrim ( open ) in TR ( pushbutton board right )S 362 Frame Button: Autotrim ( close ) in TR ( pushbutton board right )S 363 Table Amplifier for light barrier, AutotrimS 364 Table Limit switch Autotrim (close)S 365 Table Limit switch Autotrim (open)S 368 Table Changeover switch suction air blown airS 384 Tiltable table Tilt table limit switch leftS 385 Tiltable table Tilt table limit switch rightS 386 Gearbox Control switch for sweeperS 388 Table Button for sweeper ON OFFSFM CU Plug-in board: Special function - MonitorSER Switching board special electrical system carrying the relay unitV 361 Frame LED table ( open ) in TRV 383 Frame Flashing diode for light barrier AutotrimV 381 Frame Transmitter for light barrier AutotrimV 382 Frame Receiver for light barrier AutotrimY 94a Table Solenoid valve air supply ON / OFFY 366 Table Solenoid valve Autotrim (close)Y 367 Table Solenoid valve Autotrim (open)Y 370 Table Solenoid valve suction airY 389 Table Solenoid valve sweeper

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Autotrim Parts List ( from V 3.1 )

Component Position Function

K1 TR Relay Lift the front tableK2 TR Relay Lower the front tableK3 TR Relay Change-over blown air / suction airM 371 Table Compressor motor for blown air and suction airN 380 Frame Amplifier for light barrier, AutotrimQ 386 Table Overload switch for compressorS 361 TR Button Autotrim openS 362 TR Button Autotrim closeS 363 Table Amplifier for light barrier, AutotrimS 364 Table Limit switch Autotrim (close)S 365 Table Limit switch Autotrim (open)S 384 Tiltable table Tilt table limit switch leftS 385 Tiltable table Tilt table limit switch rightS 386 Gearbox Control switch for sweeper ON OFFS 388 Table Button for sweeper ON OFFS 400 TR Button Autotrim Lift the front tableS 401 TR Button Autotrim Lower the front tableSFM CU Plug-in board: Special function - MonitorSER Switching board special electrical system carrying the relay unitTR Light barrier Pushbutton plate, right-handV2 TR Flashing diode for light barrier AutotrimV3 TR LED Autotrim openV 381 Frame Transmitter for light barrier AutotrimV 382 Frame Receiver for light barrier AutotrimY 94a Table Solenoid valve air supply ON / OFFY 366 Table Solenoid valve Autotrim (close)Y 367 Table Solenoid valve Autotrim (open)Y 370 Table Solenoid valve Change-over blown air - suction airY 389 Table Solenoid valve sweeperY 390 Table Solenoid valve Lower the front table

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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 outputsignals is located on this board.

In order to activate the functions retractable side gauge and backgauge lock, the switches S1 and/or S2must be turned to 1.

LED Color MeaningGround stateV8 green +24 V ONV9 green +12 V ONP10 red Valve lift left-hand side Y 160 OFFP11 red Hy switch Y 330 OFFV12 red Valve lift right-hand side Y 158 OFFV13 red Valve VL left-hand side Y 155a OFFV14 red Valve VL right-hand side Y 155b OFFV15 red Valve - backgauge lock OFF

fixed Y 331V16 red Valve - backgauge lock OFF

clear Y 391V17 red Spare OFFV18 red Spare OFF

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Special Hydraulic System (SHM) Plug-in Board

VL = retractable side gauge

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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 hydraulicallyretractable side gauges. Both directions of motion (up / down) are now controlled hydraulically. The relevantlimit positions are scanned via limit switches. On this version, the hydraulic pressure is turned off when thegauges are lowered. Besides the mechanical and hydraulic modifications this new model requires a newspecial 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 setcorrectly.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 ON = VL available2. Switch S 2 ON = backgauge lock ON3. Switch S 3 ON = old VL version4. Switch S 4 ON = Cut optimization (must be turned on)5. Jumper JP 1 ON6. Jumper JP 2 ON7. Jumper JP 3 ON ( Pin 1+2 )

2. 176 Machines

VL control in both directions through hydraulic system (twin cylinder).

1. Switch S 1 ON = VL available2. Switch S 2 ON = backgauge lock ON (176 = OFF)3. Switch S 3 ON = old VL version4. Switch S 4 ON = Cut optimization (must be turned on)5. Jumper JP 1 OFF6. Jumper JP 2 OFF7. Jumper JP 3 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. Byconverting the hydraulic / electrical system, the VL can also be retained in its bottom position without anyhydraulic pressure. This prevents excessive heating of the hydraulic system. The setting of switches andjumpers on the SHM board is the same as on the 176 MON machine.

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Switches and jumper positions on the new SHM board

old VLwith recovery spring

The function of the key vor > lower both VL 0.0000.000< with optimalzero point or drift. Major variations between positive and negative values of driftand brake afterrun also indicate that there must be an error in the adjustment.admissible tolerances for

Drift: - 0.002 cm / sec to + 0.002 cm / secBrake afterrun: 0.000cm to 0.004 cm maximum

Mechanical check:Make sure that there is no mechanical stiffness throughout the backgauge travel. First, remove the toothedbelt from the spindle drive unit. Then slowly move the backgauge over the entire travel, using a torquewrench. The max. admissible torque of 2.5 Nm must not be exceeded in this case. If the value is higher onsome points, please check the spindle guides, spindle and backgauge support for damages. The permissibletorque of the spindle alone (friction value spindle / nut) must not exceed 1 Nm. Moreover, after activation ofthe motor brake an unimpeded rotation of the motor must be possible. This can be ensured by supplyingthe brake coil directly with + 24 V d.c. If you notice a partial mechanical stiffness, please re-adjust thebrake 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 thestatus BN 6454.1439. This includes modifying the servo board and the amplifier cable. The followingmeasure 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 toversion 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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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 threeassemblies:

1. D. c. motor 2. Tachometer generator 3. Holding brake

1. D. c. motor ( 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 theESR amplifier (terminals 1+2) via carbon brushes onto the collector. The max. adjusted voltage in thisexample 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 areabrading and this powdered carbon collects in the motor and at the collector, the motor must be sent-in tothe manufacturer for maintenance work after the carbon brushes have been changed for the third time. Themotor cannot be cleaned on site, because the relevant cleaning devices (such as ultrasonic cleaning) arenot available. Furthermore, when the motor is at the manufacturers for maintenance purposes, the bearingwill be replaced and the collector re-worked. If the motor is not serviced, the deposit of carbon dust maycause an accidental ground in the motor which results in malfunctions, or may even cause the servoamplifier to be damaged in individual cases. Since the applications of the cutting machines vary greatly itis not possible to indicate a definite period for the change of the carbon brushes. The motor should also beinspected with regard to accidental ground, before new brushes are installed or if there are temporarymalfunctions of the servo drive. In that case disconnect the motor, check both lines for connection againstthe 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 voltagegoverned 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. Pleaseobserve the contact pattern of the brushes also in this case. The generated d. c. voltage with max. speedis 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 performsonly a holding function and is consequently smaller than the brake on a machine of the same type, butwith 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 usedLenze brake as far as the function is concerned, but the adjustment of the brake air gap is different. In thepast, some motors showed broken locking pins which caused the machines to break down. This is thereason why we have been gluing the hub of the brake rotor additionally with Loctite 290 on the motor shaftsince 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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List of error messages for servo amplifier BN 6454.xxxx for optimized high-speed 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 brakingenergy, for example by constant braking action of motor.Surge limiter defective?

Elimination: Re-establish soldered fuse connection by soldering. When doing so, make sure toretain the spring force of the bimetal.

Check: under normal operational conditions the red LED of the surge limiter p.c. board must beOFF. 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, redLED 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 thecable shield. By a worn-through motor cable. By dust of the brushes which causedarcing to the motor housing.

Elimination: In case of parting of cable install a new motor cable, check the motor, take measurementwith 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 entirerotation of the motor. In case of accidental ground, replace the motor.

Important! For these measurements, the device must be turned off and the motordisconnected. In order to reset the stored display messages, the yellow and red LED onthe device, turn the mains voltage off and re-connect it.

Check: Under normal operational conditions the red LED on the motherboard or on supplementaryboard HL 6454.1439 as well as the yellow LED on the front panel must be OFF.

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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 inputsmust be at 0V, in case of a malfunction the inputs go up to approx. +14V. Eliminateaccidental 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 wastoo low and must be redefined. To do so, lock the motor. The pulse current will flow forsome seconds. After that the devices switches back to constant current and the redLED lights up. In this condition the current is adjusted to the nominal current of themotor by means of the current limit potentiometer (front panel).

Check: The ammeter should be monitored for some time throughout the intended operation ofthe machine. In any case the mean current must be sufficiently below the adjustedcurrent 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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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 isdrifting 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 themotor- 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 thetachometer 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 thetransmitter signals of channel 1 and 2.

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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 runsperceptibly rough, then turn slowly clockwise until the motor runs smoothly over thecomplete 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 thezero point. To do so, watch the motor shaft or measure the tachometer voltage.

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Conversion of connecting cable at servo amplifier

old version

Connecting cable: 8 cores + shieldingid. no. 023173 + 023174

All colored cores are twisted in pairs with a blackcore, each. All black cores are combined onterminal 20.

new version

The orange core which is twisted in pairs with theorange core is removed from terminal 20 andsupplied to terminal 12. In order to make this quitesure, strip the insulation of the cable, if necessary.das Kabel abisolieren.

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Ramp adjustment of servo drive ( as of V 6.0 )

Type of fault: With very smooth paper, error message position not reached and brake afterrunexceeding 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 servocontrol 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 Adjustpositioning

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 servicedocuments) 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: Select starting (1) or braking stage (2) in the Set positioning image. Use the + or key on the control unit to change the value.

Test: 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 fromthe data image. If there are problems, a new adjustment of the stages will benecessary.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) anddesignated as zero point. Drift of 0.000 cm / sec.= zero point has been perfectly set, servo motor is at a standstill after the positioningprocess is terminated..

However, the indicated values of drifting and maximum speed only changeafter a reference run has been performed!

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Parts list SERVO motor

CP 1 CU Plug-in board: Central Processor

CU Frame Control unit motherboard

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

M 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

T Motor Tachometer generator for SERVO motor

SERVO CU Plug-in board: SERVO control

Y17 Table Brake lifting solenoid for backgauge brake motor

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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 twomicro filters.

B. Electronic control unit:

Consisting of:1 PDR plug-in board1 CUM module8 light sensors8 amplifiers for the light sensors1 stepping switch 0 10 for pressure presetting1 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 valve2. pop valve3. pressure sensor

The proportional solenoid valve is controlled to open or close at a varying degree by means of the currentvia 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 hasalso been factory set to 25 28 bars. This setting cannot be made when the unit is installed. ( From thefront, a correction within a range of + / - 3 bars can be made). Safety clamping pressure or clamping barspeed are adjusted in the usual way. (Please, refer to the sticker on the frame pillar containing the hydraulicsystem).The pressure sensor is required for the data acquisition for the electronic system. Its temperaturecompensation 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 moduleand the PDR plug-in board.

Sensor amplifier 1 - 4, plug no. 825 CUM unitSensor 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 unitplug no. 702 CUM unit

Pressure sensor control block hydraulic systemDiode plug 6 - pin. PDR board

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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. theclamping pressure is adjusted according to the position of the preselection switch.

Clamping pressure selector switch set to 10:

on POLAR 115 / 137 = 4500 kpon POLAR 155 = 5500 kpon POLAR 176 = 6000 kp

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P1 Control unit for automatic clamping pressure regulation

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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 materialalignment 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 machinetypes 92 to 176.This tables includes all the pressure values (stepping switch 0 10) which are combined with all thesensor 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 ofmachine, 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 thesetting 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 theindividual amplifiers. When the sensor is covered the LED at the relevant amplifier (24 V d.c.) lights up. Ifno sensor is covered, all the LEDs are OFF (0V). If a readjustment is necessary, because an amplifier orfiber optic cable has been replaced or when extremely dark cutting material has been used, the sensitivitycan be modified at the amplifier potentiometer (amplifiers are installed under the machine table) beneaththe 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 thepressure 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 thelight fiber cables under the table.

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Instructions for setting the PDR board

Switch machine off . Wait, until main motor is at a standstill. Connect pressure sensor for pressuregauge 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 is0 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 daNPOLAR 155: 130 bar = 5500 daNPOLAR 176: 138 bar = 6000 daN

2. Press both cut buttons again, and use potentiometer V max to set the on-indicator pilot light onthe 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 example100,000 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 tostage 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 runthrough.Once the teach-in program is terminated, set the operating switch to 0 position. The operating programis activated and the display of the PDR board shows the number of activated sensors and the preselectedclamping pressure stage.

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 machineis 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 deviatemore from the preset values.In case of an error in the internal control of the PDR board or the pressure sensor (on hydraulic controlblock) an emergency operation will be switched on. The clamping force will then be set to approx. 80 % ofthe 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 PDRplug-in board, program version V 2.0 is suitable for all machines equipped with the optional automaticclamping pressure regulation.

Version V 2.0 includes all the features of the preceding versions (fully-automatic) and the additional newoperating mode emergency operation.With this operating mode, the pressure can be manually adjusted, if the sensors in the control block aredefective 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 dN137: 103 - 106 bar = approx. 4500 dN155: 125 - 130 bar = approx. 5500 dN176: 135 - 138 bar = approx. 6000 dN

5. For setting the minimum clamping pressure turn the stepping switch to 0, then turn the Sizeswitch to position 1 or F . Trigger a clamping action by pressing the cut buttons. Withposition 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 Sizeswitch to 0 position.The adjusted pressure values are saved and can be activated any time with the clamping pressurestepping switch (0 10). These values remain stored even when the machine is turned off.

Mon op GB 01 06.02.2006


PDR board

Mon op GB 01 06.02.2006


P 1 Oil Cycle ( 1-channel ) with proportional pressure regulating valve

Mon op GB 01 06.02.2006


Connecting plan - automatic clamping pressure regulation

emc-mon_op_gb_06.02.04

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