EMC2 Electric

EMC2_gb2 03.05.
1998
Technical Training
for
EMC II
EM
SD - P
(Types 92, 115, 137, 155)
Imprint: File name: EMC2_gb2

First edition: 03.05.1998
Applicable for: Types SD, SD-P, EM, EMCII
Author: Harald Gutwald
Scope: 72 pages
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EMC2_gb2 03.05.1998
Table of Contents
TECHNICAL DATA ..................................................................................................................................... 3
POWER MODULE ..................................................................................................................................... 4
SECONDARY AC VOLTAGES OF THE MAIN TRANSFORMER ............................................................... 5
STRUCTURE OF CONTROLS .................................................................................................................. 7
DESCRIPTION OF PLUG - IN BOARDS ................................................................................................... 8
POWER SUPPLY (PS 5 AND PS 24) ......................................................................................................... 9
CONTROL PANEL (CP) ........................................................................................................................... 10
LIGHT BARRIER (LS) ............................................................................................................................... 11
BLOCK DIAGRAM OF LIGHT BARRIER ................................................................................................. 12
BOARD AR - POSITIONING COMPUTER ............................................................................................... 13
INTERFACE POSITIONING COMPUTER (IAR) ...................................................................................... 14
HARDWARE CHANNEL (HK) .................................................................................................................. 15
MONITORING CHANNEL (KK) ................................................................................................................ 16
SEQUENCE OF FUNCTIONS FOR CUTTING ........................................................................................ 17
ADJUSTMENT OF THE LIMIT SWITCHES ON THE GEAR BOX (SNAP-ACTION SWITCH) ................ 18
INTERFACE MAIN COMPUTER (IHR) .................................................................................................... 20
PULSE FORMER FOR MEASUREMENT SYSTEM (TAM) ...................................................................... 21
LINEAR MEASURING SYSTEM (LMS) ................................................................................................... 22
EAROM INTERFACE (EI) ....................................................................................................................... 23
MOTOR CONTROL (MC) ......................................................................................................................... 24
HYDRAULIC SYSTEM (HY81) ................................................................................................................. 25
DESCRIPTION OF FUNCTIONS ............................................................................................................. 29
OPTIONAL HYDRAULICS ....................................................................................................................... 31
P1 - OIL FLOW CIRCUIT ......................................................................................................................... 32
P2 - OIL FLOW CIRCUIT ......................................................................................................................... 35
CONTROL UNIT HYDRAULIC 81 ............................................................................................................ 40
KNIFE UPSTROKE CONTROL AND 2-CHANNEL HYDRAULICS (HY 91) .............................................. 41
KNIFE UPSTROKE CONTROL ................................................................................................................ 43
P1 OIL FLOW CIRCUIT WITH HYDRAULIC 91 ....................................................................................... 45
P2 OIL FLOW CIRCUIT WITH HYDRAULIC 91 ....................................................................................... 46
CONTROL UNIT HYDRAULIC 91 ............................................................................................................ 47
CONTROL DIAGRAM FOR CUTTING AND CLAMPING OF POLAR SD, SD-P, EM AND EMC
BEFORE MACH. NO 5232530 ................................................................................................................ 48
CONTROL DIAGRAM FOR CUTTING AND CLAMPING OF POLAR SD, SD-P, EM AND EMC
AFTER MACH. NO 5232530 .................................................................................................................... 49
LIST OF COMPONENTS ......................................................................................................................... 50
SERVICE INFORMATION FOR REPAIRS ON POLAR LINEAR MEASURING SYSTEM ........................ 54
SEQUENCE OF FUNCTIONS FOR BACKGAUGE POSITIONING ......................................................... 55
SERVICE INFORMATION FOR SELECTING PROGRAM Ø ON CUTTING MACHINES
WITH DIGITAL DISPLAY .......................................................................................................................... 59
OVERVIEW OF ERROR DISPLAY FOR POLAR 55, 58, AND 76 EM ...................................................... 63
DIAGNOSIS COMPUTER ........................................................................................................................ 68
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EMC2_gb2 03.05.1998
Technical Data
Dimensions of POLAR models Backgauge speeds of POLAR machines
POLAR 76 Width: 152cm (59 1/8) with side tables

Deep: 175cm (68 1/8) 152cm (59 1/8) POLAR 76 EM forward fast 8,2 cm/sec.
Height: 140cm (55 1/8) forwrd slow 2,7 cm/sec.
Reverse fast 8,2 cm/sec.
Deep: 211cm (79 1/8) 212cm (83 1/2)
Height: 147cm (57 1/8) POLAR 76 SD forward fast 8,2 cm/sec.
Deep: 211cm (79 1/8) 212cm (83 1/2)
Height: 147cm (57 1/8) POLAR 92, 115, 137, 155 EM / EMC
POLAR 137 Width: 254cm (100) with side tables forward fast 15,8 cm/sec.
Deep: 282cm (111 1/16) 288cm (113 3/8) forwrd slow 2,7 cm/sec.
Height: 165cm (64 15/16) Reverse fast 15,8 cm/sec.

Deep: 295cm (116 1/8) 355cm (139 3/4) POLAR 92, 115, 137, 155 SD
Height: 173cm (68 1/8
forward fast 10,0 cm/sec.
Weights and floor loads of POLAR machines
POLAR 76 Weight complete: 1040 kg (2288 lbs)

Frame: 720 kg (1584 lbs)
Table: 285 kg (627 lbs)
Floor load: 650 daN /m2
Spec. contact area load: 1,5 daN /m2
Dynamic surcharge: 15%



Spec. contact area load: 2 daN /m2

2m Table: 1830 kg (4026 lbs)
* daN = kp
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EMC2_gb2 03.05.1998
POWER MODULE
NOTE: TURN-OFF MACHINE (MAIN SWITCH) WHEN WORKING ON POWER MODULE!
The power module containing all components for the power supply of the machine control system consists of
main distributor (PMD), fuse board (PMF), main transformer and rectifier unit (PMR). The three-phase power
lines from the main switch and the star-delta switch are protected by 3 fuses 10 amps each on the distributor
board. The whole control system can be adapted to standards
of different countries by inserting respective fuses.The items
connected to these fuses are the backgauge motor, the blower
motor, the fluorescent lamp for the working table and the main
transformer. The transformer is switched an by a relay (K304)
on the main distributor board. The relay is actuated by pressing
the key control ON located at the right-hand top of the front
panel, after star-delta switch has been turned to position delta
. When the machine is turned off, the relay is de-energized
turning the transformer off as well. For adjusting the control
voltage to differing mains voltages the main distributor offers
the possibility to operate the primary side of the transformer
either between two phases (position) 220VAC) or between
one phase and neutral (position) 380VAC). Precision
adjustments possible by changing the connection to the fuse
board in the following way:
Rough adaption Fine adaption

Mains with plug on main with Jumpers on
distributor fuse board
200 V 220 V 200 V

210 V 220 V 200 V
220 V 220 V 220 V
230 V 220 V 220 V
240 V 220 V 240 V
250 V 220 V 240 V
260 V 220 V 260 V
350 V 380 V 200 V

380 V 380 V 200 V
400 V 380 V 240 V
420 V 380 V 240 V
440 V 380 V 260 V
500 V* 380 V 220 V
600 V* 380 V 220 V
* requires step down transformer for control system.
All unused connector pins of voltage taps should be covered with the respective plastic caps.
If connections are changed re-insulate the unused pin with a cap.
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EMC2_gb2 03.05.1998
Secondary AC voltages of the main transformer
SECONDARY USED FOR FUSE (PMF)

VOLTAGE (AC)
40V Magnetic valves (+42VDC) 6,3A slow (F4)
32V PS5/PS24 (+5,1 VDC/+24VDC) 6,3A slow (F1)

15V/30V FIXOMAT (special equipment)
15V/20V -12VDC/-30VDC (WSP) 1A slow (F8)
-12VBDC/-30VBDC (EI) 1A slow (F6)

12,5V Optical cutting-line indicator 2 x 4A slow (F3, F5)
11,5V +9VDC (CP) 4A slow (F2)
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EMC2_gb2 03.05.1998
The rectifiers for the secondary voltages 40V AC, 32 V AC and 11,5 V AC are on the heat sink in front of
the main transformer.
The board mounted on the heat sink contains the following items:
a) Stabilising of voltage supply +9V DC for control panel (CP).
b) Rectifiers, smoothers and stabilisers for -12V DC, -30V DC, -12VB DC, and -30VB DC used
on EAROM Interface (EI) board and Interchangeable Data Storage (WSP).
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EMC2_gb2 03.05.1998
STRUCTURE OF CONTROLS
The machine functions are controlled by three calculator boards.
1. MAIN COMPUTER (HR)
The main computer forms the head of the control system, thus directing all logical and arithmetical opera-
tions between the two sub-computers (positioning computer and keyboard computer). The data exchange
with the positioning computer is achieved via an I/0 port. The keyboard computer is connected through a
serial interface.
2. POSITIONING COMPUTER (AR)
The positioning computer (AR) controls the backgauge movements and cutting cycle. The respective posi-
tioning and cutting commands are given by the main computer. To control the motor logic (ML) and the
cutting circuit the static I/0 lines are connected from the boards front side through the positioning compu-
ter interface (IAR) to the base plate.
3. KEYBOARD COMPUTER (BR)
The keyboard computer controls all the keys of the board for the operating unit (BT) and the board for the
special functions of the operating unit (BSF), resp. When a key has been actuated the keyboard computer
codes the information transmitting it to the main computer via a serial interface.
It is also via this serial interface that the main computer sends to the keyboard computer the commands
for indicating numerical values on the digital displays and for switching the LEDs ON/OFF.
These 3 plug-in boards are equipped with EPROMs which store the data for the machine functions.
The storage expander board (SPE) is also equipped with EPROMs. They contain the microprocessor pro-
gram. Furthermore, this board contains RAMs for the data exchange between main computer and posi-
tioning computer.
On each EPROM of these 4 boards there is an adhesive label carrying a date or a program version.
The data or the program version, resp., marked on the labels must be the same for all 4 boards,
otherwise the cutter will not work.
The machine is permanently monitoring various functions and operating modes.

In case of any malfunction the respective number (Error Code) is indicated in the nominal display (please,
refer to Service Information). As soon as an error number is displayed all machine functions are blocked.
The error number is cancelled by switching the control voltage off and turning it on again.
Starting with version V 1.0 the error number can also be cancelled by actuating the AUTOMATIC OFF
key.
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EMC2_gb2 03.05.1998
Description of Plug - In Boards

Test Point
24V
42V
0V
5V

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EMC2_gb2 03.05.1998
POWER SUPPLY (PS 5 and PS 24)

The power supply boards are stabiliser circuits operating according to the principle of pulse width
modulation.
They furnish: a) + 5,1 V DC (PS5) to run the control logic except the keyboard computer
b) +24 V DC (PS 24) for command devices and cutting circuit
In order to serve as an input voltage of the power supply boards the secondary voltage of 32 V AC from
the main transformer is rectified and smoothened in the power module. The input voltage for board PS 5 is
decoupled by means of a diode and backed up by a 10,000 µF capacitor which supplies the energy
required for saving the current machine data when control voltage is turned off (data saving).
Moreover, the PS 5 board contains two voltage sensors which will initiate data saving after the control volt-
age has been turned off, and supply a reset pulse for main and positioning computer after switching the
voltage on. (Pin 9,10,11 +5V Reset Pulse - Pin 6, 8 Restart)
The board PS 24 is protected by a fine wire fuse (4 A slow).
The output voltages of both boards are monitored by a green LED, each, and can be measured at the test
sockets at the front sides of the boards.
The output voltages are set to the following values by the factory:
PS 5: + 5,08 V - + 5,12 V
PS 24: + 23,9 V - + 24,1 V
The old typ of board can be re-adjusted, if necessary, by means of the potentiometer next to the
test sockets. The new types (see below) are not adjustable, if voltage is incorrect they must be replaced.
PS 24
PS 5
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EMC2_gb2 03.05.1998
CONTROL PANEL (CP)
The control panel consists of the boards for keyboard computer (BR), operating unit (BT) and
special functions of operating unit (BTS, only for EMC), respectively.
The secondary voltage of 11,5V AC is rectified in the power module and stabilised to +9V DC (+/-0,6VDC).
The power module transmits this +9 VDC as a supply voltage directly to the control panel. This voltage can
be measured at the test sockets at the left-hand side of the board operating unit and is used for operat-
ing the displays and LEDs.
The supply voltage of the keyboard computer is produced from the +9V DC on the BT board. It is set by
the factory to + 5,1V (+/-20mV) and can be re-adjusted by means of the potentiometer located underneath
the test sockets for +9 V. The test sockets for the +5,1 V are located on the upper part of the BT board,
next to the LED which indicates that the voltage supply is turned ON.
The switches at the upper part of the BT board have the following functions:
Switch Position Function

S2 A without correction
S2 B with correction
S3 A measuring system = metric
S3 B measuring system = inches
S4 A decimal point = cm
S4 B decimal point = mm
With the correction (S2) the displayed measurements are rounded up or down, resp., within a range of
+/- 0,08mm.
The service jumper is established by connecting both pins and is used for checking purposes
(refer to Manual Service Information).
Switch S1, on some boards installed, was never used !
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EMC2_gb2 03.05.1998
LIGHT BARRIER (LS)
The lightbarrier uses an invisible, infrared light of a wavelength of 950 nm.
The lightbarrier board (LS) is accommodated in the left-hand lightbarrier housing. The receivers are
located at the same place whereas the transmitters are located within the right-hand lightbarrier housing.
Voltage supply is ensured by a +12V DC stabilisation on the LS board supplied by +24V DC.
The transmitter diodes emit light pulses at a frequency of 1,000 Hz. 3 diodes, each, are connected in
series with LEDs 1, 3 and 5 working in phase opposition to LEDs 2, 4 and 6. The functioning of the trans-
mitter diodes can be checked by means of 2 red light-emitting diodes (V 13 for transmitters 1, 3, 5 and
V 15 for transmitters 2, 4 and 6) on the LS board. The voltage drop to be measured at each transmitter
diode is approx. 1V DC. Any malfunction in the oscillator output in phase opposition will be indicated by a
lighting of LED V1.
On the receiver side, the incoming light pulses are transformed into electrical signals by photo pin diodes
and later digitised by means of downstream amplifiers.
The electronic system consists of two similar and independent units working in parallel. The circuit com-
pares frequency and phase position of the signals received with the respective signals transmitted, estab-
lishing an logic level if the signals are identical. In order to be able to detect any short circuits of the out-
puts the two logic levels are exclusive OR. Two LEDs to be clearly seen from outside will indicate the
output levels (V10 red and V8 green).
For localising a channel which has broken down the Lightbarrier board is furnished with 6 small LEDs
(V2-V7),which are slightly glowing during normal operation and will light brightly in case of any interruption
or failure of a channel.
The lightbarrier housings are adjusted in the factory in such a way that upon installation a correct repro-
ducible mounting is ensured. In case any beam requires readjustment the p.c. boards of the transmitting
and receiving diodes, resp., can be displaced after loosening the fastening screws in front of the barrel of
the lens to achieve exact focussing. With the correct position the a/c. voltage at the receiver diode
will reach a maximum value. The minimum value is 150 mV measured across the individual receiver
diodes.
The correct adjustment of the lightbarrier can be checked either by measuring the voltage at each of the
receivers or by performing several cuts with the service jumper on the LS board connected. Prior to any
clamping procedure or knife movement the positioning computer (AR) carries out a lightbarrier test
by shortly switching off the transmitter diodes. Within 40 ms the lightbarrier must react by the condition
interruption. Otherwise, the lightbarrier test has not been passed and the respective error number (83) is
indicated in the keyboard display.
With the 10-channel version of the lightbarrier (LS-10) the additional transmitter diodes are connected in
series with the two transmitter groups. The receiver side is extended by 4 channels. The LS 10 is basically
functioning in the same way as the 6-channel version.
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EMC2_gb2 03.05.1998
Block Diagram of Light barrier
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EMC2_gb2 03.05.1998
Board AR - Positioning Computer
only POLAR 76
without D5 und D6
16 KB - Eproms
only POLAR 76
without D5 und D6
128 KB - Eproms
D5 D6
POLAR S, SD-P, EM, EMC

RAB, TR, Grippersystem
16 KB - Eproms
D5 D6

RAB, TR, Grippersystem
128 KB - Eproms
D5 D6
RA2 - RA7, TR, Grippersystem
Jumper for Resetfunction
Jumper set by 1 -3 = Reset by PS5

POR
Jumper set by 2 -1 = internal Reset
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EMC2_gb2 03.05.1998
INTERFACE POSITIONING COMPUTER (IAR)

The positioning computer interface board forms a connection between the static inputs and outputs at the
front side of the positioning computer and the base plate. For this purpose it is necessary to adjust the
signals of the command devices to the voltage level of the positioning computer. For controlling the conical
magnetic valve (Y315) and the magnetic valve Air supply ON (Y94) the board contains two electronic
amplifier stages.
With machines SD, SD-P and 76 EM, resp., the two switches on the board interface positioning compu-
ter are used for changing the display (metric / inches) and the decimal point (mm/cm). The jumper for
service purposes is only used with machines SD-P and 76EM, resp. (refer to Service Information).
The following inputs and outputs of the board can be monitored by means of light-emitting diodes (LEDs):
LED no. Colour Meaning with LED ON Basic condition
V1 red Cutting buttons actuated OFF

V2 red light barrier test positive OFF
V3 red SB solenoid not energized ON
V4 yellow Gear limit switch S22b actuated ON
(top dead centre)
V5 yellow Clamp at top position (B29) ON
V6 yellow Cutting-line indicator (S309) OFF
V7 yellow Backgauge advance movement (S10) OFF
V8 yellow Backgauge reverse movement (S14) OFF
V9 yellow Manual precision adjustment (S18) OFF
V10 yellow Key Air supply ON (S87) OFF
V12 red Conical valve (Y315) energized OFF
V19 red Energize magnetic valve clamp (Y27) OFF
V23 red Energize magnetic valve clutch (Y33) OFF
V27 red Magnetic valve Air supply OM (Y94) energized OFF
Service-Jumper
only 76 EM / SD-P
Decimalpoint
mm / cm
Only for machines

without KC
Display
inches / metric
Page 14
EMC2_gb2 03.05.1998
HARDWARE CHANNEL (HK)
Parallel to the positioning computer the hardware channel board contains the sequential control for the
cutting circuit. The CMOS elements are supplied with + 12V DC generated out of +24V DC by means of a
solid state voltage stabilizer installed on the board. For the control of the safety bolt solenoid (SB) an
electronic stage is employed. The I/0 signals can be checked by their respective LEDs at the front side of
the boards, having the following meanings:
LED No. Colour Meaning with LED ON Basic condition
V1 green + 12V DC ON
V2 yellow Knife delay timing over OFF
V3 yellow Cut release ON
V4 yellow SB normally closed contact (B.SBE) ON
V5 yellow SB normally open contact (B.SBA) OFF
V6 yellow Cut button, right-hand side (S28a n/c) ON
V7 yellow Cut button, left-hand side (S28b n/c) ON
V8 yellow Cut button, right-hand side (S28a n/o) OFF
V9 yellow Cut button, left-hand side (S28b n/o) OFF
V10 yellow Automatic knife activated OFF
V11 yellow Gear limit switch S22a activated OFF
(bottom dead centre)
V12 yellow Lightbarrier ok. ON
V13 yellow Position knife change (S340) OFF
V14 red Cutting button activation valid OFF
V15 red Energize magnetic valve clutch (Y33) OFF
V16 red SB solenoid energized OFF
V17 red Energize magnetic valve clamp (Y27) OFF
V18 red light barrier test positive OFF
HK - Card without automatic knife - part no. 016331
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EMC2_gb2 03.05.1998
MONITORING CHANNEL (KK)
The monitoring channel (KK) compares the output signals of the cutting circuit control of positioning
computer (AR) and hardware channel (HK), respectively. Only if these signals of the two channels are
identical the clocked pulses will be supplied for the two symmetric push-pull transducers which supply the
energy for magnetic valves Y27 (P1 for clamping) and Y33 (P2 for clutch).
The transformers of the push-pull transducers are mounted on the base plate of the CU port. The secon-
dary voltages of the transformers are rectified on the monitoring channel and supplied potential free to an
electronic stage which allows the valve inductivity to be switched off extremely rapidly. The energizing of
valves Y27 (P1) and Y33 (P2) is indicated by two red LEDs (V4 and V5).
When the output signals of positioning computer and hardware channel are not identical the monitoring
channel will generate one reset signal, each, indicated by two red LEDs (V2 and V3) at the front side of the
board. At the same time, the magnetic valves Y27 and Y33 are switched off. In case that - due to a defect
in the cutting circuit - the two resets are not able to restore the initial condition of positioning computer and
hardware channel, resp., the LEDs will not be extinguished; an error message (number 85) will be indi-
cated and any further energizing of the valve is blocked.
The voltage supply (+ 12V) of the monitoring channel is generated on the hardware channel board and
indicated by a green LED (V1).
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EMC2_gb2 03.05.1998
SEQUENCE OF FUNCTIONS FOR CUTTING
The sequence of functions for cutting can be checked by means of the LEDs on the hardware channel.
Condition (sequence) LED No.
1. Cutting permission from positioning computer (AR) 3 ON
2. Press both cutting buttons within 0,5 sec. 6+7 OFF

8+9 ON
3. Cut buttons actuated correctly shortly 14 ON
4. Lightbarrier test demanded by positioning computer (AR) 12 OFF

If light barrier test positive 18 ON
5. Output Clamping (pin 27AC:O-Signal) 17 ON

(control of Y27 (P1) from monitoring channel KK)
-KNIFE DELAY TIME -
6. Signal knife delay over from position. computer (AR) 2 ON
7. Energizing of safety bolt (SB) 16 ON
8. Proximity switch bSB.E opens 4 OFF

Proximity switch b5B.A closes 5 ON
9. Output knife (pin 26AC:O-Signal) 15 ON

control of Y33 (P2) from monitoring channel (KK)
-KNIFE DESCENDING
10. Knife at bottom dead centre (b22a actuated) 11 ON
11. Safety bolt SB de-energized 16 OFF
12. Output Y27 of KK de-energized (pin 27ac + 1 2V) 17 OFF
-KNIFE RISING -
13. Knife at top dead centre (b22a in resting position) 11 OFF
14. Output Y33 of KK is de-energized (pin 26ac + 1 2V) 15 OFF
15. Reset for stored signal lightbarrier test positive 18 OFF
16. Reset for stored signal cut buttons actuated correctly 14 OFF
(only if automatic knife is not activated; LED 10 OFF)
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EMC2_gb2 03.05.1998
Adjustment of the limit switches on the gear box (snap-action switch)
Attention !
Adjust as exact as possible, because of the snap-action switches !
1. Switch machine off !
2. Pull out plug no.10 with SD, EM and EMC machines.
3. Turn knife carrier down manually until the mark (1) of the positive switch-cam corresponds with the
mark (2) on the gear box.
4. Move the upper switch (3) with screwdriver (5) in axial direction (a) slowly, until the measuring
gauge (Ohm-meter) shows contact. Fix switch again.
5. Move lower switch (4) with screwdriver (5) in axial direction (a) until reaching the catch (contact
report). Thereafter move switch in axial direction (b) until in measuring gauge (Ohm-meter) the
contct report disappears. Fix switch again.
6. Plug mentioned in point 2 should be put together again.
7. Switch on cutter again. Check position of knife carrier in upper dead point. Correct if necessary.
Page 18
EMC2_gb2 03.05.1998
el. TDC
Additional description of the
mech. TDC
cutting cycle in EMC / EMC 0° / 360°
Monitor machines
el. BDC
mech. BDC
180°
<6%
&XWWLQJ
<
&ODPSLQJ
<
<

1. Actuating of the cut buttons 5. Knife in electric TDC
2. Pre pressing time over 6. B29 recognize the clamp
3. Start of knife 7. Y315 is switched off
4. Knife in electric BDC
Page 19
EMC2_gb2 03.05.1998
INTERFACE MAIN COMPUTER (IHR)
Through the Interface Main Computer (IHR) board the static I/0 lines as well as the serial interface to the
keyboard computer (BR) are connected from the front side of the main computer to the base plate.
For this purpose, it is necessary to adjust the signals of the command devices to the voltage level of the
main computer. The board contains an electronic amplifier stage with a red LED indicator (V1) for the
control of the air valve (Y94a) at the front air table.
To adjust the control to the machine size a pre-selector decade switch is used. The machine identification
will ensure that the minimum and maximum values of the backgauge path monitored by the control system
will correspond to the actual machine size.
Setting must be done before turning the control system on,

according to the following codes:
Switch position Machine size
0 76
1 92
2 115
3 137
4 155
5 155 with 2m table
6 137 with 2m table
7 no limit
Machines EM and EMC include programmable unused additional functions for the synchronization and
control of peripheral devices which are connected via relay on the interface main computer board to plug
no. 17 of the base plate.
When special functions are performed the relay contacts will be closed for approximately 0.5 sec.
Page 20
EMC2_gb2 03.05.1998
PULSE FORMER FOR MEASUREMENT SYSTEM (TAM)
In this module the 0-degree and 90-degree pulses coming from the linear scale are multiplied by four in
order to increase the resolution accuracy. They are transformed into forward and backward pulses then
being counted by a 6-decade counting chain. During every backgauge movement the positioning computer
(AR) checks the counter within a program cycle.
Every time the backgauge moves over the reference point of the linear scale the preset reference mea-
surement, set by the decade switches on the TAM card, is loaded into the counter chain. Setting of the
refernce position is already described in Service manual 3.
In the case of machine types EM and EMC the reference point need not be moved over after the control
system has been turned on. If the machine has been switched off with the backgauge stopped the current
backgauge position is stored in a non-volatile storage on the EAROM Interface (EI) board. As soon as
the machine is turned on again, the main computer will load this latest position into the counting chain.
The board is fitted with 3 red LEDs which have the following functions:
LED V1: flashes during every backgauge movement

LED V2: is lit during advance movement of backgauge
LED V3: is lit for approx. 0.5 sec. when the reference point is passed over
NOTE: If, after switching off the machine a) the backgauge was moved
or
b) board EI was replaced
or
c) work on sledge,brake or backgauge
the backgauge must be run over the reference point after the machine has been turned on.
If the machine was switched off with the brake released, the reference point also has to be passed over,
subsequent to machine start-up.
Button for manual

Reference position
Id.No. 016232
and later
Decade
Switches
not on boards with

Id.-no.: 016233 and
later versions
Page 21
EMC2_gb2 03.05.1998
Linear measuring system (LMS)
During the backgauge movement the scanner head of the linear scale supplies 0 - degree and 90 degree
pulses, resp., which are than multiplied by four by the TAM - Card resp., and added to (return ) or sub-
tracted from (advance) the counter chain.
The quadruplicating of the pulses results in a measuring accuracy of one counting pulse per 0.01 mm of
backgauge path. Every time the backgauge passes over the reference point (centre of scale) the value
adjusted at pre-selection switches S1...S5 is entered into the counter chain (reference value) by means of
a pulse. The basic condition for achieving precise counting pulses is the correct calibration of the mea-
suring sledge with regard to the glass scale, i.e. the gate plate in the measuring sledge must be parallel to
the counting bars on the glass scale. These counting bars are not perceptible with the naked eye. Their
width is 0.02 mm. The distance between two counting bars is also 0.02 mm. These counting bars con only
be recognised on the gloss scale as grey stripes which are approx. 8 mm high. The mechanical calibration
of the measuring sledge as well as the electrical calibration of the counting signals are performed in the
factory by means of special devices upon the production of the linearity scales.
In the field the linear measuring system con be checked by using the calibration set, id. no. 020364. This
calibration device makes it possible to check whether the scanner head supplies counting pulses, or if the
reference point is recognised by the scanner head. Moreover, measurements can be carried out, if the
setting pulse for the counter chain is located in the centre of the reference signal. This is indicated by the
bar graph within the calibration device. By means of the adjusting screw mounted onto the measuring
sledge it is possible to re-adjust the sledge and thus the parallel arrangement of the gate plate and the
glass scale. Detection of errors during backgauge positioning can be done by using the reference testing
instrument, ident number: 023797.
Verstärkergehäuse
amplifier housing
Sendedioden Empfängertransistoren
emitter diodes receiver transistors
Gitterplättchen
Glasmaßstab gate plate
glas ruler
Page 22
EMC2_gb2 03.05.1998
EAROM INTERFACE (EI)

The EAROM Interface contains the logic operation between main computer and interchangeable data
storage (WSP). The interchangeable data storage is connected to the front side of the EAROM interface
board via the base plate and a flat wire harness.
The board as such contains further storage elements holding the following data:
- last backgauge position

- brake afterrun
- dimensions of the special false clamps
- multiplicator of margin adjustment (only EMC)
- cut counter (only EMC)
All storage elements are non-volatile (EAROM), i.e. the data stored are saved even after the supply
voltage has been cut off.
Supply voltages used are +5V and -12V. For erasing and storing new data, resp., an additional - 30V is
required which is needed only for a short time and can be checked by means of a red LED (V1).
The negative voltages are generated in the power module (PM) from two secondary voltages (15V / 20V)
of the main transformer and afterwards rectified and stabilized in the PMR unit. The negative voltages for
the storage elements of the EAROM interface board are branched off the negative voltages for the
interchangeable data storage and supported by means of a capacitor. This is why these voltages are
designated - 12VB and -30VB, respectively, (B = buffered).
At the test sockets at the front side of the board the

following voltages can be measured, from top to bottom:
Tolerance:
TP 1 -12V (-11V to -13V)

TP 2 -30V (-28V to -32V)
TP 3 -12VB (-11V to -13V)
TP 4 -30VB (-30V to -35V)
TP 5 0V
If one of the two negative voltages for the interchangeable data

storage fails a red LED (V6) on the EI board will light and further
operations with the storage will not be possible for safety reasons.
NOTE: In case the EAROM interface board is replaced the following values have to be re-entered:
- dimensions of the special false clamps
- multiplicator of margin adjustment (only EMC)
- cut counter (only EMC)
Moreover, the backgauge must be run over the reference point after the machine has been
switched on.
Page 23
EMC2_gb2 03.05.1998
MOTOR CONTROL (MC)
The MC unit controls the backgauge motor and the blower motor, if the latter is part of the equipment.
The unit is composed of a base plate and the motor logic (ML) plug-in board. The motors are protected by
overload protectors and short-circuit protectors which are set according to the motor performance and
voltage.
Three semiconductor relays (V1M, V2M and V3M) control the three-phase AC for the backgauge motor.
The relay (K11M and K15M) are used for selecting speed and direction of the motor.
The control of the switching devices and the +24V DC brake solenoid for the backgauge motor is per-
formed by the motor logic (ML) board. The input for the motor logic is supplied by the positioning computer
via the positioning computer interface and are connected from the CU unit to the MC unit by means of a
flat cable. The motor logic includes various safety locks, e.g. for ensuring that the motor cannot be started
unless the brake magnet control is working.
The limit switches for the backgauge movement are controlling the motor and the brake, resp., according
to the backgauge direction. The respective front limit switch will be selected by the position of the false
clamp switch and by the Fixomat, if existing.
The LEDs at the front side of the board have the following meanings:
V1 Backgauge movement slow

(K11M de-energized)
V2 Backgauge advance movement
(K15M de-energized)
V3 Special false clamp 1 inserted (S218)
V4 False clamp inserted (S6)
V5 Brake magnet energized (Y 17)

V6 Front limit switch
(OFF, when activated)
V7 Rear limit switch

(OFF, when activated S 13)
V8 Backgauge motor energized
Page 24
EMC2_gb2 03.05.1998
Hydraulic System (HY81)
The hydraulic system 81 installed on all EM/EMC II models differs essentially from the hydraulic systems
of the former models. It comprises the following devices:
1 gear pump
1 control unit P1
1 conical valve P1 (Y315)
1 ball type magnetic valve P1 (Y27)
1 working cylinder
1 control unit P2
1 additional flow governor P1 (only 92)
1 inching valve P2
Arrangement
The entire system is located in the right hand

frame pillar which serves also as oil tank.
Except for the pump and the inching valve
all devices are placed above the oil level.
Inching
Pressure
regulation
Page 25
EMC2_gb2 03.05.1998
The Pump
The pump is a gear pump with one inlet through

which the oil is sucked in via a filter. The pump has
two outlets, i.e. P1 (= clamping) and P2 (= clutch).
It is driven by the main motor by means of a V-belt.
Care should be taken that the pump does not run dry,
as this will result in its breakdown. Also the direction
of rotation must be as prescribed as otherwise the pump will fail.
The Working Cylinder
On system 81 the working cylinder is mounted vertically and screwed to the

rear side of the pillar. When exchanging a cylinder please see that there will
be no gap between cylinder and cylinder support.
If necessary, insert spacer discs. The working method of the cylinder is the
same as described for the preceding version.
The tubes routed within the frame pillar are connected

with the cylinder housing to which the baseplate with
control units and valves is mounted. The complete base
plate with the control units can be taken off by unscrewing
4 screws. It is sealed by means of O-rings.
Page 26
EMC2_gb2 03.05.1998
Control units
Flow circuit P1 (= clamping) comprises 3 devices which can be exchanged separately in case of possibly
arising malfunctions. Flow circuit P2 (= clutch) has only one control unit.
Flow circuit P1 Flow circuit P2
1 . Control unit P I The control unit P2 comprises

2. M1 conical valve (Y315) the following components:
3. M3 ball type magnetic valve (Y27)
X = filter
The control unit P1 comprises the W = manometer connection P2
following valves and slide valves: M2 = ball type magnetic valve (Y33)
Z = pressure relief valve for
a) pressure relief valve for clutch pressure
safety pressure
b) control slide valve
c) pressure regulating valve
d) flow governor
e) switch piston for high- and
low pressure range
f) manometer connection P1
Page 27
EMC2_gb2 03.05.1998
The inching valve
The inching valve is mounted within oil flow line P2. It reduces the clutch pressure during the knife change
and is actuated via a bowden wire by pulling the turn knob for clamp pressure regulator.
Additional flow governor (only 92)
The additional flow governor reduces the speed of the clamp descent when the cut buttons are actuated. It
is located within the oil flow line P1 and connected above the pump by means of a T-piece.
Control unit for special hydraulics
On machines equipped with hydraulically controlled optional equipment (stacklifts, retractable sidegauges
and hydr. backgauge lock) an additional control unit is required which is mounted to the base plate by
means of flanges. Sealing is achieved by O-rings.
The control unit for optional hydraulics comprises the following components:
1. switch over valve (Y330)

2. pressure relief valve for optional hydraulics
3. conical valves
Page 28
EMC2_gb2 03.05.1998
Description of functions
On the hydraulic system 81 the two oil flow circuits P1 (= clamping) and P2 (= clutch) are designed in
such a way that they do not influence each other in their function. This is achieved through the use of two
separate control units for P1 and P2. The clamp pressure is now adjusted by means of a control knob
located at the upper right side of the front plate. Via a cam it actuates a bowden wire which controls the
pressure regulating valve.
Circulation
When the main motor is switched on and the V-belt fitted, the pump is delivering oil. The pump transfers
the oil through the two oil flow circuits P1 (= clamping) and P2 (= clutch) via the control units back to the
tank with a circulation pressure of 1 - 2 bar.
Actuation of the mechanical cutting line indicator
Upon actuation of the pedal a cam presses the slide-valve into control unit P1, thus interrupting the con-
nection of P1 to the tank. Switch S309 is actuated via a second cam. Thereby the plug-in-board AR
(positioning computer) energises the conical valve Y315 to open the line to the working cylinder so that the
oil can flow in. In P1 the pressure pre-adjusted at the relief valve for safety pressure builds up and the
clamp moves down. The speed of its downward movement depends on the value adjusted at the flow
governor of control unit P1 . When the pedal is released, the control slide valve moves back to its initial
position restoring the connection of P1 to the tank. Now the spring draws the clamp upwards and the oil in
the working cylinder is pressed back to the tank via conical valve Y315 and the control slide valve.
The positioning computer keeps conical valve Y315 energised until the clamp has returned to its resting
position and proximity switch B29 is activated.
Clamping without cut
The function clamping without cut becomes initiated by actuating the cut buttons which causes the
magnetic valves Y27 and Y315 to become energised. Magnetic valve Y27 blocks the oil circulation to the
tank whereas magnetic valve Y315 opens the line to the cylinder. The pressure within P1 rises and the
piston rod is driven out of the cylinder. As soon as the clamp hits the material or the table surface, the
pressure within P1 rises further. At an oil pressure between 20 and 40 bar the switching piston for high-
and low pressure-range reacts.
Its function is as follows: If a pressure of 40 bar is reached, the switching piston will direct P1 to the
high-pressure circuit which is supplied by the pump and appears at the pressure regulating valve, the
conical valve, and within the cylinder (- this pressure corresponds with the adjustment at the control-knob)
and a low pressure circuit with a maximum pressure of 40 bar.
This pressure appears at the ball type magnetic valve Y27 which blocks the oil circulation to the tank. With
cut buttons released ball type magnetic valve Y27 becomes de-energised opening the line for the oil of P1
to flow back into the tank.
The conical valve Y315 remains energised until the clamp has returned to its upper position and B29 is
activated.
Page 29
EMC2_gb2 03.05.1998
Cutting
Upon actuation of the cut buttons the two valves Y27 and Y315 of circuit P1 become energised first as
described above. With time delay after the valves of P1, ball type magnetic valve Y33 of P2 is energised.
The delay time for Y33 may be varied by a potentiometer. After magnetic valve Y33 has been energised,
the knife strikes down. When the knife has passed bottom dead centre the two valves Y27 and Y315
become de-energised by the limit switches S22a, S22b and the control circuit, which leaves the clamp
remaining in its lowered position, as the de-energised conical valve Y315 blocks the line from the cylinder
to the tank. Controlled by the limit switches at the gearbox the knife strikes upwards. After having returned
to top dead centre, the ball type magnetic valve Y33 of circuit P2 becomes de-energised and the knife
stops. At the same time the conical valve Y315 becomes energised again and the clamp returns to its
upper resting position. At the end of the cycle conical valve Y315 becomes de-energised when B29 is
activated.
In case a down-stroke of the knife is interrupted, all three magnetic valve instantly be-
come de-energised. Knife and clamp will stop immediately.
Knife change
For function Knife change the control knob must be pulled first. This has the effect that:
- caused by actuation of micro-switch S340 , the display for the actual backgauge
position starts flashing.
- by means of a bowden-wire the inching-valve is operated
With the inching-valve operated the pressure for the clutch is reduced, which makes it easier to
inch the knife to bottom dead centre. Prior to inching the knife down, the clamp must be lowered by
actuating the footpedal. With microswitch S340 actuated the conical valve Y315 becomes de-energised
immediately after the pedal is released.
Page 30
EMC2_gb2 03.05.1998
Optional hydraulics
All optional hydraulics are arranged within oil circuit P2. If pressure is required for operation of one of
the optional hydraulic functions, the PC-board SH first energises the magnetic switch-over valve
Y330 and thereafter the respective conical valve.
The switch-over valve then connects the optional hydraulic with the pump while the conical valve opens
the line and allows the oil to flow into the repective cylinder.
At the same time cutting and clamping operations are blocked electrically and hydraulically.
For an operation to be performed by the optional hydraulic system no pressure is required, only the
respective conical valve is energised. The switch-over valve Y330 remains de-energised.
Bleeding the hydraulic system
Caution !
The slightest amount of air in the hydraulic
system may cause malfunctions.
Page 31
EMC2_gb2 03.05.1998
P1 - Oil Flow Circuit
- Circulation -
clamp cylinder with

pressure reduction unit
conical valve Y315
reduction valve
slide for mechanical

cutting line indicator
relief valve for

safety pressure
clamp pressure
regulating valve
ball type safety

valve Y27
Pump
P1- circuit
flow governor
Page 32
EMC2_gb2 03.05.1998
- Clamp Movement by Pedal -
clamp cylinder with

conical valve Y315
reduction valve

relief valve for

safety pressure
clamp pressure
regulating valve
ball type safety

valve Y27
Pump
P1- circuit
flow governor
Page 33
EMC2_gb2 03.05.1998
- Operation of Clamp during Cut -
clamp cylinder with

conical valve Y315
reduction valve

clamp pressure relief valve for

regulating valve safety pressure
ball type safety

valve Y27
flow governor
Pump
P1- circuit
Page 34
EMC2_gb2 03.05.1998
- Circulation -
Stacklift 1 Stacklift 2
clutch cylinder conical conical

valve valve
12 sec. Y 160 12 sec. Y 158
slege -
clamping unit
ball type valve
Y33 (cutting)
storage
tank
retractable side
2 - 3 ccm
gauge (VL)
Y331
Filter P2
relief valve for conical Y155a = VL (left
clutch pressure valves Y155b = VL (right)
slege
switching valve
Y330 (cut /opt. hy)
relief valve for

optional hydraulics
inching valve
(knife change)
Pump
P2 - circuit
Filter Ø 1,55 mm
Page 35
EMC2_gb2 03.05.1998
- Operation of Clutch Cylinder during Cut -

valve valve
12 sec. Y 160 12 sec. Y 158
ball type valve

Y33 (cutting) storage
tank
2 - 3 ccm retractable side
Y331 gauge (VL)
Filter P2
slege
switching valve
Y330 (cut /opt. hy)
relief valve for

optional hydraulics
inching valve
(knife change)
Pump
P2 - circuit
Filter Ø 1,55 mm
Page 36
EMC2_gb2 03.05.1998
- Operation of Clutch Cylinder during Knife Change -

valve valve
12 sec. Y 160 12 sec. Y 158
ball type valve

Y33 (cutting) storage
tank
2 - 3 ccm retractable side
Y331 gauge (VL)
Filter P2
slege
switching valve
Y330 (cut /opt. hy)
relief valve for

optional hydraulics
inching valve
(knife change)
Pump
P2 - circuit
Filter Ø 1,55 mm
Page 37
EMC2_gb2 03.05.1998
- Operation of Stacklift (upward movement) -

valve valve
12 sec. Y 160 12 sec. Y 158
ball type valve

Y33 (cutting)
storage
tank retractable side
2 - 3 ccm gauge (VL)
Y331
Filter P2
slege
switching valve
Y330 (cut /opt. hy)
relief valve for

optional hydraulics
inching valve
(knife change)
Pump
P2 - circuit
Filter Ø 1,55 mm
Page 38
EMC2_gb2 03.05.1998
- Operation of Stacklift (downward movement) -
conical conical
clutch cylinder
valve valve
12 sec. Y 160 12 sec. Y 158
ball type valve

Y33 (cutting)
storage
tank retractable side
2 - 3 ccm gauge (VL)
Y331
Filter P2 conical Y155a = VL (left
relief valve for valves Y155b = VL (right)
clutch pressure
slege
switching valve
Y330 (cut /opt. hy)
relief valve for

optional hydraulics
inching valve
(knife change)
Pump
P2 - circuit
Ø 1,55 mm
Filter
Page 39
EMC2_gb2 03.05.1998
Control Unit Hydraulic 81
Page 40
EMC2_gb2 03.05.1998
Knife upstroke control and 2-channel hydraulics (HY 91)
Knife upstroke control and two-channel hydraulic for the machine types 76, 92, 115, 137 and 155 that are
sold in Germany and England.
The following elements are new:
Electric:
1. Adapting transformer BV6328 Id.No. 228755 for 92, 115, 137 and 155 machines.
Adapting transformer BV6324 Id.No. 228759 for 76 machines.
(The transformers are equipped with additional winding (24V) for control box.
2. 4 proximity switches Ø 8mm
3. MHY control sheet bar with housing
4. Adapter of the plugs CU - unit 2, 4, 6, 9, 15, on plug 431.
5. Two connecting cables with plugs for the magnetic valves Y27a and Y33a. For POLAR 76 is only
one cable for the magnetic valve Y27a in addition.
Mechanics:
1. A hydraulic control unit with 2 supplementary ball safety valves Y27a and Y33a for machines 92,
115, 137, 155.
2. A hydraulic control unit with additional ball safety valve for the 76 machines.
3. Four cam disks
4. One holding plate for the proximity switches.
The four cam disks are numbered 1 to 4 and pinned together. They can be adjusted as in the past for the
upper dead point position max. around 20mm. The proximity switches are also numbered and mouted with
a distance of 0,6 - 0,8 mm to the cam disk. (This typ of proximity switch are differend to all others. They
will only detect a small area, so adjacent cams are not detected.
Control Knife Upstroke

The control sheet bar MHY, that is mounted in a housing on the rear side of the machine column, has its
own voltage stabilization 24V= for the proximity switches and 5V= for the electronic elements as well as for
the relays K1 and K2 (DIL-Relays). The control voltage of about 24V for the MHY-control comes from the
adapting transformer over the terminal X1, 14 and 15. It is fused with a 1A inline fuse. The single signals of
the proximity switches are two - channelled.
Page 41
EMC2_gb2 03.05.1998
The control voltage of about 24V for the MHY control comes from the adapting transformer over the
terminal X1, 14 and 15. It is fused with a 1A inline fuse. The single signals of the proximity switches are
two - channelled.
The relays K1 and K2 for the control knife upstroke are activated by means of the two transistors and they
emit the OT- and UT- signals.
Control of the two - channel Hydraulic
Two relays K3 and K4 are connected parallel to the magnetic valves Y27 and Y33 (adapter plug no. 6)
By means of the a contcts of the relay K3 the magnetic valves Y27a and 33a are activated with a
separate voltage supply of 42V = (CU - unit 2.14 and 15).
The same MHY control board is used for the Polar 76, but without the relay K3, because the magnetic
valve Y33 does not exist (Id.No. 024671). The only delivered spare part is the fully tipped MHY with Id.No.
024657.
The relays K3 and K4 for the control of the supplementary magnetic valves Y27a and Y33a are forced
conducted and have self operation. The b contact of relay K3 is looped in the line of the safety bolt
resting position CU 9.8. The b contact of relay K4 is grinded in the line of the cut buttons 28a opener,
switch 15.8. The following texts and error numbers are displayed by interruption of the self checking
operation.
EMC - Monitor machines:
cut buttons to be released, safety bolt to be unlocked.
EMC II, EM machines
error no. 88 (monitoring switch SB, relais K3).
error no. 90 (open cut button S28a, relais K4)
76 EM / SD-P
error no. 90 (open cut button S28a, relais K4)
Two Channel Hydraulic 91
Two supplemental ball safety valves Y27a (clamping) and Y33a (cutting) are inserted for the hydraulic
control. The magnetic valves Y27a and Y33a are connected parallel to the former magnetic valves Y27
Y33. Thats the reason why all the time 2 magnetic valves have to be activated, one for pressure and one
for cutting, to close the hydraulic oil circuit to the tank.
The Polar 76 has only one additional ball safety valve Y27a (pressure) mounted parallel to Y27, because
the electro-magnetic clutch for cutting is already controlled by two inspected relays.
Page 42
EMC2_gb2 03.05.1998
Knife upstroke control
The four cam disks are numbered

1 to 4 and pinned together.
They can be adjusted as in the
past for the upper dead point

position max. around 20 mm.
The proximity switches are also
numbered and mouted with a

distance of 0,6 - 0,8 mm to the
cam disk.

$
9 9
7UDQVIRUPHU 9 a
9 9 0+6/RJLF
9 9
%%
Switching sequence of proximity 9 9
switches during cutting
1. Knife downstroke (electrical)

2. Knife upstroke (electrical)
3. Knife afterrun (mechanical)
Sequence of operation (crank arm)
a. knife in basic position (upper dead center)

b. knife in cutting stick (lower d.c. mechanically)
c. knife upstroke (lower dead center electrically)
d. switch of knife movement (de-energizing
magnetic valves)
Page 43
EMC2_gb2 03.05.1998
Controls of the 2-channel Hydraulic
control for Connection to MHY - MHS Logic

relay K4
CU 10.4
CU 15.8
CU 9.8 CU10.5 MHS.3 MHS.1

control for CU 10.1 CU 10.2
relay K3
K3 (MHY) K4 (MHY)
Page 44
EMC2_gb2 03.05.1998
P1 Oil Flow Circuit with Hydraulic 91
Page 45
EMC2_gb2 03.05.1998
P2 Oil Flow Circuit with Hydraulic 91
Page 46
EMC2_gb2 03.05.1998
Control Unit Hydraulic 91
Switch over valve

for
optional hydraulik
Page 47
EMC2_gb2 03.05.1998
Control diagram for cutting and clamping of POLAR SD, SD-P, EM and EMC
before mach. no 5232530
Page 48
EMC2_gb2 03.05.1998
Control diagram for cutting and clamping of POLAR SD, SD-P, EM and EMC
after mach. no 5232530
Page 49
EMC2_gb2 03.05.1998
List of components
Part No. Arrangement Electrical Components
BR CP keyboard copmuter
BT CP keyboard and display
BSF CP keyboard for additional functions
CP frame control panel
CU frame control unit
PS 5 CU plug board voltage supply +5V d.c.
PS 24 CU plug board voltage supply +24V d.c.
SPE CU plug board storage expander
TAM CU plug board puls former for lenght measuring system
HR CU plug board main computer
IHR CU plug board main computer Interface
AR CU plug board positioning computer
IAR CU plug board positioning computer interface
EI CU plug board EAROM interface
KK CU plug board monitor channel
WSP CU plug board exchangeable data storage
HK CU plug board hardware channel
LS frame light barrier pulseforming and monitoring
LSV frame light barrier emitter distributer plate
LMS table length measuring system
MC frame control unit for backgauge motor and connection for blower
MHS conduit upstroke control for knife
ML MC plug in chart for motor control logic
OH frame control unit for optional hydraulic equipment
PM frame power modul
PMD PM power modul distributor board
PMF PM power modul fuse board
PMR PM power modul rectifier board
SDS frame star-delta starter for main drive motor
SE frame control unit for special electric equipment
SH OH plug board for optional hydraulik
TL LS push-button plate left (optional equipment)
TR LS push-button plate right (optional equipment)
A1 frame junction box for mains (three phases)
B.SBA frame monitoring sensor safety bolt retracted
B.SBE frame monitoring sensor safety bolt in blocking position
BSF. R1 BSF potentiometer: gripper margin no.I
BSF. R2 BSF potentiometer: gripper margin no.II
BSF. R3 BSF potentiometer: label correction
BSF. R4 BSF potentiometer: clamping time adjustment
BR. S2 BR selector switch: correction of measurement
BR. S3 BR selector switch: display in metric or inch mode
BR. S4 BR selector switch: decimal point cm / mm
Page 50
EMC2_gb2 03.05.1998
BT.H1 BT buzzer
B29 frame proximity switch for upper position of clamp
C.V CU motor run capacitor for fan
CU.T1 CU transformer for cutting circuit
CU.T2 CU transformer for clamping circuit
E39 frame flourescent lamp with starter
E42a frame lamp for optical cutting line indicator
E42b frame lamp for optical cutting line indicator
F.V CU fuse 1A for fan
IHR.K1 IHR control relay for special equipment
IHR.K4 IHR monitor relay for automatic backgauge
IHR.S1 IHR identity switch for machine size
K1A ML relay: backgauge brake monitor
K1M SDS supply contactor
K3M SDS star contactor
K5M SDS delta contactor
K1T SDS time lag relay
K11M MC relay: Bachgauge motor express - slow
K15M MC relay: Bachgauge motor forward - backward
K22a/b MHS auxiliary relays for cutting and clamping
K304 PMD relay: control voltage on
L38 frame choke coil for flourescent lamp
M3 frame main motor
M17 table backgauge motor
M93 table air turbine motor
M.V CU fan
PM.C1 PM charging capacitor for +42 V d.c.
PM.V1 PM rectifier for +42 V d.c.
PM.V2 PM rectifier for +9 V d.c.
PM.V3 PM rectifier for +5 V d.c. / +24 V d.c.
PM.V4 PM discoupling diode
PM.Z1 PM filter for supply voltage
PMD.F1 PMD main fuse 3 x 10 A
PMF.F1 PMF fuse 6,3 A for 32 V a.c.
PMF.F2 PMF fuse 4,0 A for 11,5 V a.c.
Page 51
EMC2_gb2 03.05.1998
PS24.F1 PS24 fuse 4A for + 24V d.c.

Q2 frame master switch
Q92 MC overload switch for air turbine motor
Q96 MC overload switch for backgauge motor
S6 clamp contact for false clamp
S8 table limit switch: forward with false clamp
S9 table limit switch: forward
S10 table contact: forward ON / backgauge brake OFF
S13 table limit switch: backward
S14 table contact: backward
S18 table contact Backgauge brake OFF
S22a gear limit switch: cutting and clamping
S22b gear limit switch: cutting and clamping
S28a table push button: cutting and clamping
S28b table push button: cutting and clamping
S41 frame switch for cutting line indicator
S87 table momentary switch: air table on
S156a TL push button: retractable side gauge - left down -
S156b TL push button: retractable side gauge - left and right down -
S156c TL push button: retractable side gauge - left or both up -
S161a TR push button: stacklift right up
S161b TR push button: stacklift right down
S162a TL push button: stacklift left up
S162b TL push button: stacklift left down
S217a table limit switch: forward with 1st additional false clamp
S217b table limit switch: forward with 2nd additional false clamp
S218 clamp contact fpr additional false clamps
S292 frame push-button: star / delta - control voltage on
S309 frame switch at pedal for clamp (Y315)
S340 frame switch for knife changing
S360 a/b table limit switch forward stop with false clamp and FIXOMAT
S390 frame switch at pedal (advance in automatic mode)
S 0,001cm TAM matching switch for reference measurement 0,001 cm
S 1cm TAM matching switch for reference measurement 1 cm
S 10cm TAM matching switch for reference measurement 10 cm
SDS.F2 SDS overload relay for main motor
SDS.FL1 SDS fuse 4A for star - delta starter
SDS.FL3 SDS fuse 4A for star - delta starter
SH.S1 SH switch: backgauge clamping ON - OFF
Tr. PM control transformer
TAM.S1 TAM push button: reference measurement
V35 frame light barrier: emitter diodes
V36 frame light barrier: receiver diodes
Page 52
EMC2_gb2 03.05.1998
V1M MC semi conductor relay for backgauge motor

Y17 table backgauge motor: lifting solonoid for brake
Y27 frame magnetic valve for clamping
Y33 frame magnetic valve for cutting
Y94 table magnetic valve for air table
Y94a table magnetic valve for air front table
Y155a frame magnetic valve for retractable side gauge left down
Y155b frame magnetic valve for retractable side gauge right down
Y158 frame magnetic valve for stack lift right up
Y160 frame magnetic valve for stack lift left up
Y315 frame magnetic catching valve for clamp
Y330 frame change over valve (cutting or optional hydraulic)
Y331 frame magnetic valve for backgauge clamping
Y.SB frame safety bolt solenoid
Page 53
EMC2_gb2 03.05.1998
Service Information for repairs on Polar Linear Measuring System
Having examined a large number of linear measuring systems which had been sent back,
we decided it was necessary to write again on the faults and their causes in positioning the backgauge in
cutting machines.We are of the opinion that linear measuring systems are replaced in many cases without
eliminating the actual cause of the error.
One must distinguish clearly how the defect is described by the customer as manifesting itself.
Is it differences in the backgauge position (cutting inaccuracy), or differences between the pre-selected set
position and the actual position reached? In order to make it easier to understand, we have developed a
scheme called Function sequence for backgauge positioning. This shows that this is made up of a
combination of electronic, electromechanical and mechanical components.
The circuit begins in the comparator (computer) as a command signal via ML (motor logic) or PI (positi-
oning interface) boards to the backgauge motor and motor brake. The backgauge motor moves the back-
gauge via the spindle and the spindle nut.
The following mechanical components enter the circuit:
- motor
- motor brake
- V-belt tension
- spindle-bearing arrangement
- spindle greasing
- spindle nut
- plug adjustment
- backgauge guide
- and the necesssary greasing.
The backgauge movement is transformed into counting signals by the linear measuring system and con-
veyed to the TAM (preparation of cycle data for measuring system) or P1 board via the cable and plug -
connections in the control unit. It is crucial here that the linear measuring system is correctly installed, i.e.
parallel to the backgauge guide and with the correct distance to the measuring head and measuring body.
The following electronic errors can appear..
- Counting signals from linear Measuring System are missing or jump intermittently
- faulty trailing cable
- faulty plug-connections or soldering joints in the Control Unit.
The counting pulses which are received by the TAM or PI boards are edited electronically and conveyed to
the comparator (computer).
Page 54
EMC2_gb2 03.05.1998
Sequence of Functions for Backgauge Positioning
Display
set value actual value
comparator (computer)
ML / PI TAM / PI
backgauge motor control unit

motor brake
plug-
- spindle
connectors
- nuts
- bearings
- lubrication
cable
backgauge
guide,
lubrication
LMS
scanner head
Page 55
EMC2_gb2 03.05.1998
In a second scheme, the possible applications can be seen for testing instruments (for service purposes)
which have been recommended by POLAR and can be obtained from our spare parts department.
These testing instruments should be available in every agency and should be employed for localisation of
possible errors:
We are dealing here with the following special testing instruments..
1. Counter monitor (ID No. 019386)
A testing instrument to measure the uncorrected backgauge position directly under the electronic counting
chain in the TAM or PI board. This testing instrument, produced since 1982, can be used in TAM bards
with the Id. numbers 016230, 016231 and 016232 or with PI boards 020140, as only these bards are
equipped with the necessary test plugs. In the case of TAM or PI boards with higher Id. numbers, use of
the counting monitor is no longer possible as the test set connections can no longer be used.
It is advisable to carry one of the above mentioned boards together with the counting monitor.
2. Adjustment set (ID No. 020364)
Was developed to enable independent replacement of the measuring head. A service testing instrument to
check correct counting function (advance, return) as well as the correct position of the measuring back-
gauge in relation to the glass scale, and if necessary to adjust it. One can also check the functioning of the
trailing cable with this instrument. The adjustment set has been on offer from Polar since 1985 and can
only be used with Polar linear measuring systems.
3. Reference testing instrument (ID No. 023797)
This instrument is a new development for linear measuring systems which can detect and register varia-
tions in backgauge position, including variations in position which occur intermittently. In addition, a testing
appliance is integrated into this instrument for the measuring cable, with which the particular plug-in con-
nectors can be checked, and a break of a single conductor can be detected.
The instrument works in the following way:
The counting pulses from the linear measuring system are compared with the counting pulses from
a pulse generator which is mounted on the driving wheel of the spindle. The single adjustment of
the testing instrument at the spindle ascent is carried out by means of a reference run.
Machine function is not influenced by this instrument. As a consequence, one can identify and register
differences in position which intermittently appear over a longer period of time during normal operation.
Page 56
EMC2_gb2 03.05.1998
Display
set value actual value
comparator (computer)
1
counting
ML / PI TAM / PI monitor
backgauge motor control unit

motor brake
- spindle
plug-
connectors
3
- nuts
- bearings reference testing
- lubrication instrument for
LMS, Tester for
LMS trailing
cable cable
backgauge
guide,
LMS
lubrication scanner head
2 adjustment set for LMS
Page 57
EMC2_gb2 03.05.1998
In the scheme entitled Measurement errors, one can see the division of the two error groups. One can
check the error demonstrated as measurement not reached or by a flashing display in the service
program (EMC/EM Monitor) or program 0 in the EMC; 76 EM; 55/58 EM by first looking at the brake
after-running and the creepage path of the backgauge.
Measurement Error
Machine indicates Set and actuel values display

Measurement not reached correspond, but backgauge
Display flashes position is wrong.
structural elements to be checked structural elements to be checked

mechanical electrical mechanical electrical
to check the structural
elements, brake after-
running and creepage
path can be called up
in the service program
- motor brake - ML - board spindle has axial play linear measuring
- spindle - PI - board spindle nuts have play scale, scanning
- spindle nuts - IAR - board LMS not corr. aligned head, TAM card,
- spindle bearing - MC - unit measuring head not PI-board, Plug-
- backg. guide - semi conductor aligned or distored. connection,trail-
- lubrication - relays Guide for scannerhead ling cable,control
- belt tension - contactors bearings worn out. unit,Ref.measure-
set values - support screws - relay K11,12,15 ment not adjusted,
Coating of glass scale
- motor bearings - computer boards demaged. HF-disturbances.
brake after-running
0,25 - 0,5 mm
creeping path / cm
55...76 = 1,0 - 2,5 values outside of tolerance values within tolerance

92 ..176 = 1,5 - 3,5
If the displayed values do not correspond to typical values for machines, the parts under the heading structural
components. must be examined, or faulty parts adjusted or replaced. We know from experience that with,
this error group, extremely few cases happen in the electronic linear measuring system.
The error manifesting as wrong backgauge position - set and actual values correspond rather indicates
counting errors or jumps in counting. Here, one must first ensure that there are no mechanical deficiencies
(see block on Mechanics) and that the setting of the basic measurement is correct, before moving on to the
linear measuring system, trailing cable and counting electronics.
Extensive instructions are sent with each testing instrument, and for this reason, we do not wish to go into
detailed handling here. You will still no doubt know this from our technical courses.
If you have any questions, we will be glad to answer them. Finally, we would recommend that you do not
generally replace the linear measuring system, but define the actual cause of a positioning error using all
available means. We are sure that with your help and observance of the above points, far fewer intact
linear measuring system will be sent in for repair.
Page 58
EMC2_gb2 03.05.1998
Service information for selecting program Ø on cutting machines

with digital display
EMC 1 All Program versions > Insert service jumper into plug-in board N-KB <
1. Indication of brake afterrun.

Switch machine on, make reference run, place backgauge on desired position.
Press pushbutton memory input (1), press pushbutton ,memory output (2);
Brake afterrun is indicated on the nominal value display. Admissible values: max. 0.6 mm
No further information can be displayed on these machines.
55 / 58 SD-P All program versions (until now)
> Insert service jumper into plug-in board CP or push switch S 7.1 to the right. <
1. Indication of brake afterrun Shortly press numerical pushbutton 1 two times;
2. Indication of slow down travel Shortly press numerical pushbutton 2 two times;
3. Indication of adjusted accuracy allowance (S8) Shortly press numerical pushbutton 3 two times;
55 EM All program versions

> In this way the display correction is switched off. <
Selection of program 0
Simultaneously press P+ and P-, program indication flashes, enter program number 0 and terminate by
,=. By means of S+ or S-, resp., you can select the steps of program 0. The values are indicated on the
nominal display
Step 1: Accuracy allowance (adjustable from 0.008 - 0.017cm by S8 on CP)

Step 2: Brake afterrun (nominal 0.025 - 0.05cm)
Step 3: Slow-down travel
Step 4: Delete programs completely (press pushbutton ,delete, then press pushbutton mark)
58 EM Program version V 1.0

> In this way the display correction is switched off.
,=. Note.. If the service jumper has not been inserted, or S 7.1 has not been switched over, the selection
of program 0 will be followed by an indication of flashing horizontal strokes in the nominal display as a
prompt to enter code number 8520. This number is acknowledged by =. By means of S+ or S-, resp. you
can select the steps of program 0.
Page 59
EMC2_gb2 03.05.1998
The values are indicated on the nominal display.
Step 1: unassigned
Step 2: unassigned
Step 3: Special false clamp (input of width + 10 mm)
Step 4: Accuracy allowance (adjustable from 0.008 - 0.017 cm)
Step 7. Air OFF via pedal, on 58 no function
Step 8: Delete programs completely (press pushbutton Delete, then press pushbutton mark)
Stop 9: Display correction (programmable; on = 0.001; off = 0.000)
Step 10: ,Air OFF upon backgauge return in manual mode, on 58 no function
Step 11: Ejector in manual mode (yes = 0.001; no = 0.000)
76EM Program versions up to V 2.0 included
> Insert service jumper into plug-in board IAR < In this way the display correction is switched off.
1. Indication of brake afterrun

Switch machine on, make reference run, place backgauge on desired position. Press pushbutton
insert position Brake afterrun is indicated on the nominal value display.
Admissible values: 0.025 - 0.050 cm
2. Selection of program 0
=. By means of S+ or S-, resp., you can select the steps of program 0. The values are indicated on the
nominal display.
Step 1: Special false clamp (width + 10 mm)
76EM Program versions V 3.0 and V 4.0
> Insert service jumper into plug-in board IAR < In this way the display correction is switched off <
Simultaneously press P+ and P-, program indication flashes, enter program number 0 and terminate by =.
By means of S+ or S-, resp., you con select the steps of program 0. The values are indicated on the
nominal display.
Step 1: Special false clamp (width + 10 mm)

Step 2: Brake afterrun (nominal 0.025-0.05cm)
Step 4: Delete program completely (pushbutton delete, pushbutton mark)
Page 60
EMC2_gb2 03.05.1998
76EM Program version V 4.1
> Insert service jumper into plug-in board IAR <

> In this way the display correction is switched off <
,=. Note: If the service jumper has not been inserted, or S 7.1 has not been switched over, the selection
of program 0 will be followed by an indication of flashing horizontal strokes in the nominal display as a
prompt to enter code number 8520. This number is acknowledged by ,=. By means of S+ or S-, resp. you
can select the steps of program 0.
Step 1: unassigned
Step 2: unassigned
Step 3: Special false clamp (input of width + 10 mm)
Step 4: Accuracy allowance (programmable from 0.008 - 0.020 cm)
Step 7.. ,Air OFF via pedal
Step 8: Delete programs completely (press pushbutton delete, then press pushbutton mark)
Step 9: Display correction (programmable; on = 0.001; off = 0.000)
Step 10: Air OW upon backgauge return in manual mode
Step 11: Ejector in manual mode (yes = 0.001; no = 0.000)
76-155 SD-P All program versions (until now)
Insert service jumper into plug-in board IAR

Switch machine on, make reference run, place backgauge on desired position. Press pushbutton
,advance slowly . Brake afterrun is indicated on the actual value display. Admissible values: 0.025 -
0.050cm. No further information can be displayed on these machines.
92 - 155 EM / EMC2 Program versions up to V 1.0 included
> Insert service jumper into board BR <

Switch machine on, place backgauge on desired position. Press pushbutton insert position
Brake afterrun is indicated on the nominal value display Admissible values: 0.025 - 0.050 cm.
Page 61
EMC2_gb2 03.05.1998
Select program 99, briefly press pushbutton P+ once, program indication shows ,0".
Selection is terminated. By means of S+ or S-, resp., you can select the program 0 steps.
Step 1: Multiplier for backgauge compensation I+II (only EMC)

> possible inputs: 0.001; 0.002; 0.003 <
Step 2: Special false clamp 1 (width + 10 mm)
92 - 155 EM / EMC 2 Program version V 2.0
Insert service jumper into board BR
By pressing pushbutton P+ or P-. , on EM also possible: press P+ and P- simultaneously, program
indication flashes, enter program number 0 and terminate by ,=.By means of S+ or S-, resp., you can
select the program 0 steps. The values are indicated on the nominal display.
Step 1: Multiplier for backgauge compensation I+II (only EMC)

possible inputs: 0.001; 0.002; 0.003
Step 4: Accuracy allowance (programmable: 0.008 - 0.020 cm)
Step 5: Brake afterrun (0.025 - 0.05cm)
Step 7: only EM, Delete programs completely
92 - 155 EM /EMC 2 Program versions from V3.0 (until now)
Insert service jumper into board BR
By pressing pushbutton P+ or P-. ,on EM also possible: press P+ and P- simultaneously, program
indication flashes, enter program number 0 and terminate by .=-By means of S+ or S-, resp., you can
select the program 0 steps. The values are indicated on the nominal display.
Step 1 Multiplier for backgauge compensation I + II (only EMC)

possible inputs: 0.001; 0.002; 0.003
Step 4: Accuracy allowance (programmable: 0.008 - 0.020 cm)
Step 5: Brake afterrun (0.025 - 0.05cm)
Step 7: Air OFF via pedal (programmable: yes = 0.001; no = 0.000)
Page 62
EMC2_gb2 03.05.1998
Overview of Error Display for Polar 55, 58, and 76 EM
In using the new software in the above mentioned machines, error monitoring of the control system was
also extended. In order to supplement the list contained in the service information, we wish to list the
current error description. Error details are related to the following program states:
55 EM to program version V 2.0

Number Cause
29 Key in operating unit keeps sticking or open circuit
39 Wrong reference measurement was set. (wrong measurement is displayed and flashes)
49 PROM - Error (machine was supplied with wrong EPROMs)
57 RAM Error on AR board (2800H - 28FFH)
58 RAM Error on AR board (3000H - 30FFH)
59 RAM Error on KDI board
68 False clamp plate size in EAROM not correct
69 Error in EAROM interface
81 Safety bolt in undefined position (SBE and SBA =1)
82 Non-return valve Y 315 in undefined position (SPU and SPR = 1) Low resistance on Y315
83 Light barrier defective
84 Non-return valve Y 315 in undefined position (SPU and SPR = 0)
85 More than 3x dynamic disagreement
86 Static disagreement
87 Cutting keys contact error (closing and opening contacts active simultaneously)
88 Safety bolt not in rest position when machine switched on
89 Cutting keys contact error (closing contacts active when machine switched on)
90 Cutting keys contact error (opening contact not closed when machine switched on)
92 Safety bolt time error (position not reached within 2 secs.)
94 Knife running time upper dead-pt./lower dead-pt. and lower dead-pt./upper dead-pt. exceeded.
Page 63
EMC2_gb2 03.05.1998
Error detection signals Meaning: Remedy:
Dashes in the digital display program The computer control system is recog- Check supply voltages on card EI
number and storage space (EM, EMC) nizing an error with the program me- Check connection card E I - CU
mory bank as soon as machine is baseplate (flat wire harness)
turned on. The complete data of the Exchange interchangeable
memory bank can be erased by acti- memory bank (WSP)
vating the key Erasing. If however Exchange card EI
the same error will appear again, the
following should be done:
Only on 76 EM: In program no. 0 a special size false See error no. -68
clamp plate has been stored, either
being smaller than 1,8 cm or larger
than 35 cm
Number -02- (EM, EMC) Error in data exchange between main Check con. plug BR 500 - CU 16
computer and keyboard computer Exchange card SPE
Main computer signals more than 3 Exchange card BR
repeat demands Exchange card HR
Number -03- (EM, EMC) Error in data exchange between main Check con. plug BR 500- CU16
computer and keyboard computer Exchange card HR
Keyboard computer receives more Exchange card SPE
than 3 erroneous signals Exchange card BR
Number -04- (EM, EMC) Keyboard computer does not receive Check con. plug BR 500 -CU16
acknowledgement from main computer Exchange card HR
Exchange card SPE
Exchange card BR
Number -05- (EM, EMC) Error within analog-digital converter Exchange card BR
of card BR
Number -06-, -08-,09-,10 Error in data exchange between key- Check con. plug BR 500 -CU16
(EM, EMC) board computer and main computer Exchange card BR
Exchange card HR
Exchange card SPE
Number -29- (SD-P, EM, EMC) Key in operating unit sticks or open Exchange Keyboard
circuit.
Number -39- (only 76 EM, SD) Preset measurement of reference Set reference point measure
point is larger than 76 cm or smaler ment correctly on the card TAM
than 7 cm. The erroneous measure- Exchange card AR
ment will be shown flashing in the Exchange card TAM
backgauge position display Exchange CU-unit
Number -49- (only 76 EM, SD) Error in the cross total of all Eprom Check and compare the Eprom
data -Version of cards AR and KDI
for conformity ?
Exchange card KDI
Exchange card AR
Number -57- (only 76 EM, SD) Error in memory component of card KDI Exchange card KDI
Number -58-,-59- (only 76 EM, SM Error in memory components of card AR Exchange card AR
Page 64
EMC2_gb2 03.05.1998
Number -67- (only EMC) Fixomat limit switch S341 and S342 Check switches and connec-
or S343 and S344 are activated simul- tions according to wiring diag.
taneously Exchange card FIX
Check connection CU-unit -
MC-unit (fiat wire harness)
Check connection MC-unit -
SE-unit (flat wire harness)
Exchange card IHR
Number -68- (only 76 EM) In program no. 0 the measurement Turn off machine. Put to rest
for a special size false clamp plate has special false clamp plate on
been stored, either being smaller than switch S6. Attach service
1,8 cm or larger than 35 cm. jjumper to card IAR. Turn on
machine. Erase complete
memory storage by using key
Program erasing and key
Erase insert correct size of
special false clamp plate into
program no. 0 of memory bank.
Check Fuse F8.
Number -69- (EM, EMC) During a read -write-or erase-func- If dashes are visible within the
tion within the program memory bank program number and storage
a data error was discovered space displays after the
machine was turned off and
,on again. Check supply
voltage on card EI. Check
connection between card EI -
CU baseplate (flat wire harnes)
Exchange interchangeable
memory bank (WSP)
Exchange card EI
Check Fuse F8
Number -80- (EM, EMC) Error in data exchange between main Exchange card AR
computer and positioning computer Exchange card HR
Number -81- The monitor switch of safety bolt is Check switch S.SB
acknowkedging both endstops at the Check connection S.SB - CU 9
same time. On machines with proximity
switches monitoring the safety
bolt: Check supply voltage for
the switches (plug 44) Check
connection IAR - AR.
(flat wire harness)
Exchange card IAR.
Exchange card AR
Page 65
EMC2_gb2 03.05.1998
Number -82- During activating of locking valve - Check connection IAR - AR

Y31 5 - the control transistor on card (flatwire-harness)
IAR does not function Exchange card JAR
Exchnage card AR
Number -83- The light barrier does not react to the Check adjustment of light
test signal before cutting cycle starts barrier (see service manual 4)
with the output condition interrupted Check connection CU4- LS 600
Check connection IAR - AR (flat
wire-harness). Protect receiver
side of light barrier against
excessive stray light
Exchange card LS
Exchange card IAR
Exchange card AR
Number -84- While locking valve - Y315 - is swit- Check supply voltage + 42 V
ched off, the voltage of + 42 V D.C. D.C. on locking valve. Check
is missing on the Control line for the connection CU 6 - locking valve
locking valve (plug 6.8) Y315. Check resistance of coil
- Y315 - for open circuit.
Check connection IAR - AR
Exchange card IAR
Exchange card AR
Check Gearbox switches
Number -85- During a cutting cycle the control Check basic condition of all
channel (card KK) will register discre- light diodes on card HK and I
pancies more than 3 times at the logic AR. Check adjustment of limit
outputs between the 2 cutting circuit switches S22a and S22b at the
channels. (hardware channel and gear box (see service manual4)
positioning computer) Check adjustment of light
barrier (see service manual 4)
Exchange card HK
Exchange card IAR
Exchange card AR
Exchange card KK
Number -86- A static discrepancy does exist bet- Check voltage + 42 V on plug
ween the output of both cutting CU 9.2 (safety bolt)
circuit channels (hardware channel Check basic conditions of
and positioning computer) LED V2 LEDs V14 - V18 HK. If one
and V3 KK are lit up permanently. of these LEDs is lit up:
Also V1 and V2 from card SPE. Exchange card HK
Check basic condition of LEDs
V1 -V3, V19 and V23 IAR .
Exchange card IAR
Check connection AR - IAR
(flat wire harness)
Exchange card AR
Exchange card KK
Check SBE Sensors
Bad Connections / Shorts
Page 66
EMC2_gb2 03.05.1998
Number -87- Normally open and normally closed Check buttons S28a and S28b
contact of a cut button are simul- and connections according to
taneously closed. wiring diagram. Exchange card
AR. Check connection AR- IAR
(flat wire harness) Exchange
card AR
Number -88- The safety bolt, without being activa- Check safety boit for mech-
ted, has left the locking position or is anical stiffness in its move-
not returning to the locking position ment. Check monitor switch
within 2 sec. after cutting cycle com- S.SB and connections acc-
pletion. Knife is not in the uppermost ording to wiring diagram.
position. Exchange card IAR. Check F1
(PS24)
Number -89- The normally open contact of one of Check cut buttons and con-
the cut buttons is in closed position nections according to wiring
when the control voltage is turned on. diagram.
Number -90- The normally closed contact of one Check cut buttons and con-
of the cut buttons is not in the closed nections according to wiring
position diagram.
Number -92- After safety bolt is activated, the un- Check safety boit for mech-
locked position is not acknowledged anical stiff ness in its move-
within 2 seconds ment. Check monitor switch
S.SB and connections acc-
ording to wiring diagram
Number -94- Knife running time upper dead Check Hydraulic circuit P2,
-pt./lower dead-pt. and lower Y330, Card SH, Card HK,
dead-pt./upper dead-pt. exceeded. magnetic clutch
Page 67
EMC2_gb2 03.05.1998
DIAGNOSIS COMPUTER
Useable for POLAR 92, 115, 137,155
EMC II Controls with EPROM versions 20.10.81, 01.03.82, 10.08.82,

V1.0 and future versions
EM Controls with EPROM versions 01.11.81, 02.03.82, 11.08.82,
and future versions
General description: The DIAGNOSIS COMPUTER will check by up to 13 steps the correct data-
transfer to keyboard computer (BR), positioning computer (AR) and data
storage boards.
For fault-finding within the cutting and clamping circuitry or within the backgauge controls TEST
POSITIONING COMPUTER and / or COUNTER MONITOR should be used.
Test step No. 1 Self-check: Test of internal Rams and ROMs
LED 1 (DIAGNOSIS COMPUTER) lit up Self check passed

LED 1 (DIAGNOSIS COMPUTER) flashing DIAGNOSIS COMPUTER defective
LED 1 (DIAGNOSIS COMPUTER) DIAGNOSIS ROUTINE will not start
does not light up Supply voltage +5V missing
No reset: replace card PS 5
Test step No. 2 Data communication with keyboard (BR)
LED 2 (DIAGNOSIS COMPUTER) lit up Test passed

LED 2 (DIAGNOSIS COMPUTER) flashing No data communication with keyboard
computer (BR) possible
Check supply voltages and connectors at
cards BR and BT
Replace card BR and BT
Test step No. 3 Test of displays:
At all displays of the control panel ascending sequences of figures (0-9) will appear alternating every
two seconds. The direction indicator is alternating in the sequence off,+ -
In case an erroneous character is displayed at one of the digits: Replace display component
In case erroneous characters are displayed at more than one digit: Replace card BT
Proceeding to next step: Activate key AUTOMATIC OFF

Acknowledgement: Dual beeping
Page 68
EMC2_gb2 03.05.1998
Test step No. 4 (read out 4 at display)

Test of operational devices at control panel
a.) When keys are activated permanently at displays will appear:
Key Display Read out Clock pulse

P+ Program 1 to 9 1 second
p- Program 9 to 1 1 second
P+, P- Program 0
S+ Storage space 1 to 9 1 second
S- Storage space 9 to 1 1 second
S+, S- Storage space 0
If there is no or a wrong reaction when keys are activated Replace card BT and/or BR
b.) On activating the remaining keys a beep will be produced and the corresponding number
will appear at the backgauge position display (refer to picture No. 1)
The digits following the decimal point will display 0.
In case of faults: Replace card BT, BSF, BR
c.) Backgauge compensation 1 and 11, cut correction (EMC only), setting of clamping time. If
position of regulators is altered figures from 0.000 to 0.0 10 will appear at backgauge position
display. Symbols +
or - will appear at direction indicator.
In case of faults: Replace card BR
d.) Alteration of operating mode at keyboard computer (BR). Read out at backgauge position
display and single beep in activation:
Selector switch: Correction of measurement display (BR.S2) 4.000

Selector switch: Metric/inch system (BR.S3) 2.000
Selector switch: Decimal point cm/mm (BR.S4) 1.000
Service jumper: 3.000
In case of faults: Replace card BR

Proceeding to next test step: Activate key AUTOMATIC OFF
Acknowledgement: Dual beeping
Test step No. 5 (read out 5 at keyboard display)

Test of microprocessor bus and RAM on card SPE
Across the common microprocessor bus a certain bit pattern is written into the RAM and checked
(refer to picture No. 2). Automatic test procedure, LED AUTOMATIC ON is lit up
No fault: Acknowledgement by dual beeping and

advancing to next test step
In case of fault: 20 beeps, number of test step is flashing,
Test concluded.
Replace card SPE
Card AR is blocking microprocessor bus: Replace card AR
Card EI is blocking microprocessor bus: Replace card EI
Page 69
EMC2_gb2 03.05.1998
Test step No. 6 (read out W at keyboard display)

Data communication with positioning computer (AR)
Automatic test procedure, LED AUTOMATIC ON is lit up

advancing to next test step.
test concluded.
Replace card AR

Test of counter on card TAM
Signal path: DIAGNOSIS COMPUTER, IHR, TAM, IAR, AR

Duration of test procedure: approx. 18 seconds

advancing to next test step
test concluded
Check connections along signal path:
Diagnosis computer, IHR, TAM, IAR, AR
Replace card TAM
Replace card AR

Test of EAROM-Interface
Attention: Do not turn off machine during test procedure

Duration of test procedure: approx. 2 1 seconds

test concluded.
Check supply voltages at card EI
Replace card EI (if necessary key in data
on program No. 0 anew)
Page 70
EMC2_gb2 03.05.1998

Test of exchangeable date storage No. 1 (Only if WSP is plugged in position 1)
a.) Test may be skipped: Activate key AUTOMATIC OFF

b.) Start of test procedure: Activate key AUTOMATIC ON
Attention: Do not turn off machine during test procedure!

Duration of test procedure: approx. 130 seconds LED AUTOMATIC ON is lit up.

In case of fault: 20 beeps, number of test step is flashing, test
concluded.
Check connections between card EI and CU
Replace card WSP
Replace card EI
Test step No. 10 (read out 1 W at keyboard display)
Test of exchangeable data storage 2 (Only if WSP is plugged in position 2)


Duration of test procedure: approx. 130 seconds LED AUTOMATIC ON is lit up.

concluded.
Check connections between card EI and CU
Replace card WSP
Replace card EI
Test of exchangeable data storage l with total erasing of all stored data
(Only if WSP is plugged in position 1)


Duration of test procedure: approx. 130 seconds. LED AUTOMATIC ON is lit up.

concluded
Replace card WSP
Page 71
EMC2_gb2 03.05.1998
Test step No. 12 (read out 12 at keyboard 12)

Test of exchangeable data storage 2 with total erasing of all stored data
(Only if WSP is plugged in position 2)

Attention: Do not switch off machine during test procedure!

No fault: Acknowledgement by dual beeping.

concluded.
Replace card WSP
Test step No. 13 (read out 13 at display)
Test of EAROM-Interface with total erasing of all stored data
Only for EM controls with EPROM versions 01. 11.81, 02.08.82


No fault: Acknowledgement by dual beeping

concluded.
Replace card EI (if necessary key in data on
program No. 0 anew)
END OF TEST (no read out a keyboard display)

LED AUTOMATIC ON is off.
Machine may be turned off.
Page 72

EMC2 Electric

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EMC2 Electric

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EMC2_gb2 03.05.

(Types 92, 115, 137, 155)

Imprint: File name: EMC2_gb2

Dimensions of POLAR models Backgauge speeds of POLAR machines

POLAR 76 Width: 152cm (59 1/8) with side tables

POLAR 155 Width: 279cm (109 3/4) with side tables

POLAR 76 Weight complete: 1040 kg (2288 lbs)

POLAR 92 Weight complete: 1860 kg (4100 lbs)

POLAR 115 Weight complete: 3240 kg (7128 lbs)

POLAR 137 Weight complete: 4120 kg (9064 lbs)

POLAR 155 Weight complete: 4950 kg (10890 lbs)

Rough adaption Fine adaption

200 V 220 V 200 V

350 V 380 V 200 V

* requires step down transformer for control system.

Secondary AC voltages of the main transformer

SECONDARY USED FOR FUSE (PMF)

40V Magnetic valves (+42VDC) 6,3A slow (F4)

32V PS5/PS24 (+5,1 VDC/+24VDC) 6,3A slow (F1)

15V/20V -12VDC/-30VDC (WSP) 1A slow (F8)

-12VBDC/-30VBDC (EI) 1A slow (F6)

11,5V +9VDC (CP) 4A slow (F2)

a) Stabilising of voltage supply +9V DC for control panel (CP).

The machine functions are controlled by three calculator boards.

1. MAIN COMPUTER (HR)

2. POSITIONING COMPUTER (AR)

3. KEYBOARD COMPUTER (BR)

The machine is permanently monitoring various functions and operating modes.

Description of Plug - In Boards

POWER SUPPLY (PS 5 and PS 24)

b) +24 V DC (PS 24) for command devices and cutting circuit

The board PS 24 is protected by a fine wire fuse (4 A slow).

CONTROL PANEL (CP)

Switch Position Function

Switch S1, on some boards installed, was never used !

LIGHT BARRIER (LS)

The lightbarrier uses an invisible, infrared light of a wavelength of 950 nm.

Block Diagram of Light barrier

Board AR - Positioning Computer

POLAR S, SD-P, EM, EMC

POLAR S, SD-P, EM, EMC

Jumper set by 1 -3 = Reset by PS5

INTERFACE POSITIONING COMPUTER (IAR)

LED no. Colour Meaning with LED ON Basic condition

V1 red Cutting buttons actuated OFF

Only for machines

HARDWARE CHANNEL (HK)

LED No. Colour Meaning with LED ON Basic condition

V2 yellow Knife delay timing over OFF

V3 yellow Cut release ON

V4 yellow SB normally closed contact (B.SBE) ON

V5 yellow SB normally open contact (B.SBA) OFF

V6 yellow Cut button, right-hand side (S28a n/c) ON

V7 yellow Cut button, left-hand side (S28b n/c) ON

V8 yellow Cut button, right-hand side (S28a n/o) OFF

V9 yellow Cut button, left-hand side (S28b n/o) OFF

V10 yellow Automatic knife activated OFF

V11 yellow Gear limit switch S22a activated OFF

(bottom dead centre)

V12 yellow Lightbarrier ok. ON

V13 yellow Position knife change (S340) OFF

V14 red Cutting button activation valid OFF

V15 red Energize magnetic valve clutch (Y33) OFF

V16 red SB solenoid energized OFF

POLAR 76 Width: 152cm (59 1/8) with side tables

POLAR 155 Width: 279cm (109 3/4) with side tables

LED no. Colour Meaning with LED ON Basic condition

LED No. Colour Meaning with LED ON Basic condition

V13 yellow Position knife change (S340) OFF

V15 red Energize magnetic valve clutch (Y33) OFF

V17 red Energize magnetic valve clamp (Y27) OFF

5. Output Clamping (pin 27AC:O-Signal) 17 ON

6. Signal knife delay over from position. computer (AR) 2 ON

9. Output knife (pin 26AC:O-Signal) 15 ON

15. Reset for stored signal lightbarrier test positive 18 OFF