Professional Documents
Culture Documents
2005
Technical Training
EM / EMC
MONITOR
Power supply
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Mon gb 01 04.04.2005
Table of contents
Monitor control unit.................................................................................................................... 3
Arrangement of boards in CU...................................................................................................... 4
Setup of control system and EM / EMC Monitor block diagram...................................................... 5
Control components and their applications................................................................................... 6
Program versions and their use EM Monitor.................................................................................. 7
Program versions and their use EMC Monitor............................................................................... 8
Details about program version V 5.0 ( 1990 Drupa ).................. .................................................... 9
Excerpt from IP 2 / 97 ( Reduction of program versions ) .............................................................. 10
Voltage supply ( Power Module ) ................................................................................................ 11
Control voltages........................................................................................................................ 12
Power Supply ( PS ) plug-in board.............................................................................................. 13
Central Processor ( CP 1 ) plug-in board ................................................................................... 15
Positioning Interface ( PI )......................................................................................................... 15
Positioning Interface ( PI ) plug-in board...................................................................................... 17
Linear measuring system.......................................................................................................... 18
Interchangeable memory and Motor Control Unit ( MCM unit )....................................................... 20
Cutting circuit ( SK ) ................................................................................................................ 21
Cutting circuit ( SK ) plug in board............................................................................................. 22
Cutting circuit ( SK ) with two-channel hydraulic system.............................................................. 23
Light barrier ( LS ) ................................................................................................................... 24
Video Controller ( VID ) and Monitor ( CRT ) ............................................................................... 25
Keyboard Computer ( KC ) and control unit ( BTM )..................................................................... 25
Timer board ( CLK ) and PMS - CARD ...................................................................................... 27
New knife change.................................................................................................................... 27
Circuit diagrams...................................................................................................................... 29
Parts lists............................................................................................................................... 37
Addendum
List of error messages and service information
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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
Mon gb 01 04.04.2005
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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Mon gb 01 04.04.2005
CP 1
Video
Monitor
Monitor
Text Version Id. No.
Prog. Version Id. No.
Monochrom Color
T 01-T 03 EG 020150
V 1.1 (1.0)
020131
"
T 02 Skand. 020150
V 1.1 (1.0)
020131
"
T 06 EG
020151
V 3.0 (2.0)
020620
"
T 06 EG
020151
V 3.0 (2.0)
020621
"
"
T 07 Skand. 020152
V 3.0 (2.0)
020620
"
T 07 Skand. 020152
V 3.0 (2.0)
020621
"
"
T 08 EG
020155
V 3.0 (2.0)
020620
"
T 08 EG
020155
V 3.0 (2.0)
020621
"
"
T 09 Skand. 020156
V 3.0 (2.0)
020620
"
T 09 Skand. 020156
V 3.0 (2.0)
020621
"
"
T 08 EG
020157
V 3.0 (2.0)
020620
"
T 09 Skand. 020157
V 3.0 (2.0)
020621
"
"
T 08 EG
020158
V 3.0 (2.0)
020620
"
T 09 Skand. 020158
V 3.0 (2.0)
020621
"
"
CP Version no longer available = see IP 2 / 97 =
T 08 EG
023590
V 3.0
020622
"
"
T 09 Skand. 023600
V 3.0
020622
"
"
T 08 EG
023610
V 3.0
020622
"
"
T 09 Skand. 023620
V 3.0
020622
"
"
T 08 EG
023591
V 3.0
020622
"
"
T 09 Skand. 023601
V 3.0
020622
"
"
T 08 EG
023611
V 3.0
020622
"
"
T 09 Skand. 023621
V 3.0
020622
"
"
T 08 EG
023592
V 3.0
020622
"
"
T 09 Skand. 023602
V 3.0
020622
"
"
T 08 EG
023612
V 3.0
020622
"
"
T 09 Skand. 023622
V 3.0
020622
"
"
T 11A EG
023593
V 3.0
020622
"
"
T 11B Skand. 023603
V 3.0
020622
"
"
T 11A EG
023613
V 3.0
020622
"
"
T 11B Skand. 023623
V 3.0
020622
"
"
T 12a
023594
V 3.0
020622
"
"
T 12b
023604
V 3.0
020622
"
"
As of V 5.0 with PMS - Card and KC V 2.1
T 08
024330
V 3.0
020622
"
"
T 08
024340
V 3.0
020622
"
"
T 08 EG
024331
V 3.0
020622
"
"
T 09 Skand.
024411
V 3.0
020622
"
"
T 08 EG
024341
V 3.0
020622
"
"
T 09 Skand.
023421
V 3.0
020622
"
"
As of V 6.0 with Kc 2.2
T 11
024840
V 3.0
020622
"
"
T 11
024850
V 3.0
020622
"
"
024841
V 3.0
020622
"
"
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Mon gb 01 04.04.2005
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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Mon gb 01 04.04.2005
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.
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
Id. No.
020622
020622
020622
020622
Comment
color, monochr.
color, monochr.
color. monochr.
color. monochr.
As of now all the CP 1 boards which are returned for repair will be retrofitted to program
status V4.4 or more recent, or replaced by new boards of the relevant program status. If a new
graphics card is also necessary for the conversion of the machine at the customers please
order this card separately.
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Mon gb 01 04.04.2005
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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Application
PMF fuse
32 V
PS plug-in board
+5 V, +24 V and +12 V
F 1 = 6.3 A
11.5 V
F 2 = 4.0 A
12.5 V
F 3 = 4.0 A
42 V
F 4 = 6,3 A
12.5 V
15 V
not assigned
42 V
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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Tolerance:
Tolerance:
Tolerance:
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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Mon gb 01 04.04.2005
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
- 15 -
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
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
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
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Positioning Interface ( PI )
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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.
* Auxiliary relay
K 12 = backgauge motor ON
K 15 = Backgauge motor forward / backward
K 11 = backgauge motor fast / slow
- 20 -
Mon gb 01 04.04.2005
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
- 21 -
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
OFF
ON
ON
OFF
OFF
OFF
ON
ON
OFF
OFF
OFF
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- 22 -
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- 23 -
( Relay K 4 of MHY )
( Relay K 3 of MHY )
Mon gb 01 04.04.2005
LIGHT BARRIER ( LS )
The light barrier works with invisible infrared light of a wavelength of 960 nm and consists of the following
parts: transmitters, receivers and the light barrier p.c. board (LS). The light barrier p.c. board is accommodated
in the left-hand light barrier housing, where the receivers are also located, while the transmitters are in the
right-hand light-barrier housing. For the voltage supply the LS board has a +12-V d.c. stabilization which
is operated at +24 Vd.c.
The transmitting diodes generate light pulses at a cycle of approx. 1,000 Hz. Three transmitting diodes,
each, are connected in series, with the transmitting diodes 1, 3 and 5 on one hand and 2, 4 and 6 on the
other hand are working in antiphase. The current running through the transmitting diodes can be checked
with the help of 2 red- colored LEDs (V13 fir transmitters 1, 3, 5 and V15 for transmitters 2, 4, 6) on the LS
board. The voltage drop to be measured for each transmitting diode is approx. 1 V d.c. Any error occurring
at the oscillator output which is in phase opposition will be indicated by the LED V1 lighting up. On the
receiver side the incoming light pulses are converted into electric signals by photo pin diodes and then
digitized by downstream amplifiers. The decoding circuitry has a double setup and works in parallel.
The connection compares receiver signals with regard to their frequency and phase positions with the
corresponding transmitter signals and generates an output level in case of conformity. The two output
levels are inversed so that short circuits in the outputs can be detected. The output levels are indicated by
2 light emitting diodes visible from outside (V10 red and V8 green). In order to localize any channel that
has been broken down the LS board is equipped with light-emitting diodes (V2 V7) which are glowing
slightly with normal operation, but are brightly illuminated when a channel fails.
The light barrier housings are adjusted at the factory which ensures that a reproducible installation is
ensured during assembly. However, should it be necessary to readjust one of the rays, the p.c. boards of
the transmitting and receiving diodes can be shifted to adjust the focus precisely, after the fastening
screws have been loosened. In the proper position the a.c. voltage at the receiver diode reaches a maximum
value.
The minimum value is 150 mV a.c., measured at the individual receiver diodes.
The correct adjustment of the light barrier can be checked with the service jumper inserted on board LS,
either by measuring the voltage at each of the receivers or by triggering various cuts.
Before each clamping process or knife movement the Central Processor (CP1) initiates a light-barrier test
where the transmitting diodes are briefly switched off. Within 40 ms the light barrier must respond with the
condition interrupted. Otherwise, the light barrier test is considered as not successful and the relevant
error is shown on the display.
Caution!
The red LED V10 is part of the safety circuit of the light barrier.
In case of a defect of the LED the green LED V8 will also go out,
which causes the cutting and clamping functions to be locked.
The two LEDs V17 and V18 are off when the light barrier is working perfectly.
They monitor the two output levels of the light barrier to the SK board.
If these levels are not inversed the LEDs will light up.
In this case, both clamping and cutting functions are locked.
- 24 -
Mon gb 01 04.04.2005
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.
- 25 -
Mon gb 01 04.04.2005
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.
- 26 -
Mon gb 01 04.04.2005
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.
- 27 -
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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Mon gb 01 04.04.2005
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Mon gb 01 04.04.2005
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Mon gb 01 04.04.2005
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Mon gb 01 04.04.2005
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Mon gb 01 04.04.2005
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Mon gb 01 04.04.2005
- 36 -
Mon gb 01 04.04.2005
Position
KC
CRT
CU
SK
CP1
PI
VID
PS
EB
RSP
LS
LSV
LMS
MCM
MHS
PM
PMD
PMF
PMR
SDS
A1
B. SBA
B. SBE
Frame
Frame
Frame
CU
CU
CU
CU
CU
CU
CU
Frame
Frame
Table
Frame
Cable duct
Frame
PM
PM
PM
Frame
Frame
Frame
Frame
BTM. S1
BTM. S2
BTM. S3
B29
CP1. G1
CP1. S1
CRT. F
CRT. R1
CU. F1
E 39
E 42a
E 42b
K 1M
K 3M
K 5M
K 3T
BTM
BTM
BTM
Frame
CP 1
CP 1
CRT
CRT
CU
Frame
Frame
Frame
SDS
SDS
SDS
SDS
Function
Keyboard Computer
VDU
Control unit motherboard
Plug-in board: Cutting circuit
Plug-in board: Central Processor
Plug-in board: Positioning Interface
Plug-in board: Video Controller
Plug-in board: Power Supply + 5 / 12 / 24 V d.c.
Cutting circuit transformer board
RAM memory
Light barrier board
Light barrier transmitter distributor board
Linear measuring system
Backgauge motor control
Knife upstroke control
Power supply unit
Power supply unit distributor board
Power supply unit fuse board
Power supply unit rectifier board
Automatic star-delta starter
Mains supply
Control sensor electro-mech. non-repeat device out of action
Control sensor el.-mech. non-repeat device in locking
position
BCD switch: clamping time adjustment
Shaft encoder: distortion
Shaft encoder: Label correction
Proximity switch clamp at top
Battery - voltage source for data saving
Reset button
2.5-amp fuse
Potentiometer: brightness control
1-amp fuse for ventilators (M.V a / b)
Fluorescent lamp with starter
Lamp for optical cutting-line indicator
Lamp for optical cutting-line indicator
Mains contactor
Star contactor
Delta contactor
Time-delay relay
- 37 -
Mon gb 01 04.04.2005
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
- 38 -
Mon gb 01 04.04.2005
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
- 39 -
Mon gb 01 04.04.2005
EM / EMC - MONITOR
SERVICE INFORMATION
LIST OF ERROR MESSAGES
- 40 -
Mon gb 01 04.04.2005
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
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
- 41 -
P.48
P.49
P.49
P.49
P.50
P.50
P.50
P.50
P.50
P.50
P.50
P.50
P.50
P.51
P.51
Mon gb 01 04.04.2005
DISPLAY
All data
unreadable
= delete =
CAUSE
REMEDY
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
Ejector run
Note
Autotrim table
open
Note
BRK ERROR
BSY ERROR
0, 1, 2, 3, 4, 5
Swivel backgauge
limit position
- 42 -
Mon gb 01 04.04.2005
DISPLAY
CAUSE
REMEDY
DUSTERROR
Jogging mark
Note
Backgauge limit
Note
EPROM - ERROR
ERROR
Wrong
Step number
Note
Wrong
program number
Note
- 43 -
Mon gb 01 04.04.2005
DISPLAY
Wrong
CAUSE
REMEDY
Error in Eltrotact
program architecture
Note
programming.
Fixomat
END OF TRAVEL
INDICAT. MISSING
Fixomat
limit switch
defective
Fixomat Function
locked
Error
Knife time preset
( as of V 6.0 )
- 44 -
Go to reference position
Check LMS and relevant cabling,
check backgauge drive unit
Replace PI board
Mon gb 01 04.04.2005
DISPLAY
CAUSE
REMEDY
I / 0 Bus Error
No pulses from
ruler
No measurement
available
Note
Light barrier
Cut was aborted because
Check light barrier light barrier was interrupted.
Light barrier
error
Position
not reached
- 45 -
Mon gb 01 04.04.2005
DISPLAY
CAUSE
REMEDY
Measurement too
big/small Note
Knife wind up
Note
Knife change
Note
Tilting backgauge
limit
During adjustment of
tilting backgauge the direction
Related limit position switch has
Been reached.
Tilting backgauge
No reaction
Turn labels
Note
Option not
available
PMS Card
Compl. unreadable
- 46 -
Mon gb 01 04.04.2005
DISPLAY
CAUSE
REMEDY
PMS CARD
re-reading error
PMS ERROR
Autom. positioning
active
Note
Clamp not
at bottom
Note
Clamping time
interrupted
Note
- 47 -
Mon gb 01 04.04.2005
DISPLAY
CAUSE
REMEDY
Program
data error
Program not
readable
Program error
Delete
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
Source program
unreadable
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
- 48 -
Remedy up to V4.4:
Clear the relevant memory or
memory area completely.
Check battery of removable memory,
Replace removable memory, replace
PI board, check voltage supply of
PS board, replace PS board
Mon gb 01 04.04.2005
DISPLAY
CAUSE
REMEDY
Source memory
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
Re-reading error
delete
- 49 -
Mon gb 01 04.04.2005
DISPLAY
CAUSE
REMEDY
Backgauge
movement locked
Delete step
Step not readable
Step Error: delete
Cutting circuit
error
Cutting circuit
interrupted
Enable cut
buttons
Cutting locked
- 50 -
Mon gb 01 04.04.2005
DISPLAY
CAUSE
REMEDY
Number of cuts
has been reached
Note
Side gauge
lowered
Note
Side gauge
time error
Side gauge
No limit position
signal
Memory contents
unreadable
Memory area
unreadable
Memory error
Delete
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
Please note!
This message may be shown
when the machine is first switched on
(put into service) and/or on
first use of a PMS card
because the A or B memories
or the PMS card has not been
initialized by a deleting procedure.
- 51 -
Mon gb 01 04.04.2005
DISPLAY
CAUSE
REMEDY
Mechanical lock
unlocked
Mechanical lock
locked
Mechanical lock
monitoring
defective
non-return valve
42 V error
SPV ERROR
Static cutting
circuit error
- 52 -
Mon gb 01 04.04.2005
DISPLAY
TXT - ERROR
PMS CARD
invalid
CAUSE
REMEDY
Replace CP 1 board
Observe
Counter for service has exceeded
maintenance interval 100,000.
Note
Inadmissible value
Note
Verify programming
Overflow
Note
Target program
data error
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
- 53 -
Verify operation
Mon gb 01 04.04.2005
DISPLAY
Target memory not
readable
CAUSE
REMEDY
- 54 -
Remedy up to V4.4:
Completely delete the relevant program
and input again. Check battery of
removable memory, replace
removable memory, replace P1 board
Check voltage supply of
PS board, replace PS board
Remedy as of V5.0:
Clear the relevant program completely and
input again. When using the A or B memory
area check battery of CP 1 board, replace
CP 1 board. Verify voltage supply to PS
board. When using the PMS - Card, check
the PMS Card, its battery, check the PMS
CARD slot, replace BTM, replace KC
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.
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.
- 55 -
Mon gb 01 04.04.2005
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).
(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!
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
- 56 -
Mon gb 01 04.04.2005
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
EM ( C ) - Monitor V...
( 1 ) Accuracy allowance
E. g.: 88888888
( 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.
- 57 -
Mon gb 01 04.04.2005
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.
- 58 -
Mon gb 01 04.04.2005
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
The Epson printers must be adjusted for program versions V 1.0, V 1.1, V 2.0, V 3.1(S), V 4.0(S) and
V 4.1(S), resp., in the following way:
Installation at EPSON FX 800 printer
1. Printer Board: Switch position (DIP - Switch)
DIP-Switch SW:
1 = PIN 1 = OFF
1 = PIN 2 = OFF
1 = PIN 3 = ON
1 = PIN 4 = OFF
1 = PIN 5 = ON
1 = PIN 6 = ON
1 = PIN 7 = ON
1 = PIN 8 = ON
DIP-Switch SW:
2 = PIN 1 = OFF
2 = PIN 2 = ON
2 = PIN 3 = ON
2 = PIN 4 = ON
Please remember to note down the changes on the customers circuit diagram
- 59 -
Mon gb 01 04.04.2005
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
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
- 60 -
Mon gb 01 04.04.2005
- 61 -
Mon gb 01 04.04.2005
- 62 -