Polar 191030 em Emc Mon Technical Training

PRAF MICROCOMPUTER TECHNOLOGIES LTD. P.O.B.
7209, Holon 5817101, Israel

Tel.: +972-3-5031045, Fax: +972-3-5031046 http://www.praftec.com E-mail: info@praftec.com
POLAR MOHR is a registered trade mark of Polar-Mohr Maschinenvertriebsgesellschaft GmbH & Co. KG
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POLAR-191030- EM-EMC-MON-TECHNICAL-TRAINING on)
Technical Training
EM/EMC
MONITOR
Setup of Control Unit
Power Supply
Description of Plug-in Boards
List of Error Messages – Service Information
PRAF Microcomputer Technologies Ltd. Confidential Company Property.

POLAR-191030-EM-EMC-MON-TECHNICAL-TRAINING Page 1 of 62 For internal use only.
PRAF MICROCOMPUTER TECHNOLOGIES LTD. P.O.B. 7209, Holon 5817101, Israel
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Table of contents
Monitor control unit ......................................................................................................................... 3

Arrangements of boards in CU........................................................................................................... 4
Setup of control systems and EM/EMC Monitor block diagram ..................................................... 5
Control components and their applications ..................................................................................... 6
Program versions and their use EM Monitor .................................................................................. 7
Program versions and their use EMC Monitor .................................................................................. 8
Details about program V5.0 (Drupa) ................................................................................................. 9
Except from IP2/97 (Reduction of program versions) ................................................................... 10
Voltage supply (Power Module) ....................................................................................................... 11
Control voltages ............................................................................................................................... 12
Power Supply (PS) plug-in board ..................................................................................................... 13
Central Processor (CP1) plug-in board ............................................................................................ 15
Positioning Interface (PI) ................................................................................................................. 15
Positioning Interface (PI) plug-in board.............................................................................................. 17
Linear measuring system .................................................................................................................. 18
Interchangeable memory and Motor Control Unit (MCM unit) .......................................................... 20
Cutting circuit (SK) ........................................................................................................................... 21
Cutting circuit (SK) plug-in board .................................................................................................... 22
Cutting circuit (SK) with two-channel hydraulic system .................................................................... 23
Light barrier (LS) ............................................................................................................................... 24
Video Controller (VID) and Monitor (CRT) ....................................................................................... 25
Keyboard Computer (KC) and control unit (BTM) .......................................................................... 25
Timer board (CLK) and PMS card ................................................................................................... 27
New knife change ............................................................................................................................ 27
Circuit diagrams ............................................................................................................................... 29
Parts lists ......................................................................................................................................... 37
Addendum
List of error messages and service information

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Control Panel Monitor

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Arrangement of plug-in cards in the CU

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Setup of control unit
The block diagram of the POLAR EMC MONITOR illustrates the structural setup of the control system. The
16-bit CP1 (Central Processor) computer board is the ”heart” of the control system. All the other plug-in
cards in the electrical installation facility beneath the machine front table are linked via two independent
bus systems with the CP1.
The exchange of data with the keyboard computer (KC) on the control panel is performed via serial
interface.
Block diagram of EM/EMC - Monitor

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Control components and their use
Title Application Machine type

PM Power Module Standard Version EM/EMC
PS Power Supply Standard Version EM/EMC
CP1 Central Processor Standard Version EM/EMC
PI Positioning Interface Standard Version EM/EMC
VID Video Controller Standard Version EM/EMC
CRT VDU Standard Version EM/EMC
SK Cutting circuit Standard Version EM/EMC
MCM Motor Control Standard Version EM/EMC
KC Keyboard Computer Standard Version EM/EMC
BTM Cont rol panel S t andard V ersion EMC
BTM Cont rol panel S t andard V ersion EM
LS Light barrier Standard Version EM/EMC
CLK Clock Standard Version EMC
SDS Automatic start-delta switch EM/EMC
(not on model 92)
CFM Special function Autotrim, gripper Monitor Connection to TRB 3BL, EM/EMC
Programmable outputs (“EXT” key)
SHM Special Hydraulic system Lifts that can be lowered EM/EMC
Monitor Side gauges, Backgauge lock
DNF S wivel /t ilt ing backgauge S wivel backgauge, titling backgauge EMC
SER Special electr. System Swivel backgauge, titling backgauge EMC
Relay plate
Servo Servo control Optimized EMC
High-speed backgauge
PDR Clamping presuure regulation Automatic EMC
Clamping presuure regulation
PMS Polar – Memory – Additional EM/EMC
System program memory

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Program Versions and their use
If the CP1 or VID plug-in card needs to be replaced because of a defect, please remember that the card
must be compatible with the machine equipment. Program versions with addition “S” can only be used with
the “optimized high-speed backgauge” optional equipment. (only on EMC)
Board KC 0185 id. No.: 020111 can only be used with versions V1.0-
V4.1. As of version V5.0 the board KC V2.1 with id. No. 023831 has been
used. As of version V6.0 the board KC V2.2 with id. No. 023832 has
been used.
Table of the existing EM – MONITOR program versions and all the available combinations
CP1 Video Monitor

Prog. Version Text Version Id. No Prog. Version Id. No. Monochrome Color
V2.0 T06 EG 020930 V3.0 (2.0) 020620 “
V2.0 T07 Skand. 020931 V3.0 (2.0) 020621 “ “
V3.1 T08 EG 020932 V3.0 (2.0) 020620 “
V3.1 T09 Skand. 020933 V3.0 (2.0) 020621 “ “
CP Version no longer available = see IP2/97 =
V4.0 T08 EG 023770 V3.0 020622 “ “
V4.0 T09 Skand. 023780 V3.0 020622 “ “
V4.1 T08 EG 023771 V3.0 020622 “ “
V4.1 T09 Skand. 023781 V3.0 020622 “ ”
V4.2 T08 EG 023772 V3.0 020622 “ “
V4.2 T09 Skand. 023782 V3.0 020622 “ “
V4.3 T11A EG 023773 V3.0 020622 “ “
V4.3 T11B Skand. 023783 V3.0 020622 “ “
V4.4 T11a 023774 V3.0 020662 “ “
V4.4 T12b 023784 V3.0 020662 “ “
As of V5.0 with PMS Card and KC V2.1
V5.0 T08 EG 024350 V3.0 020622 “ “
V5.1 T08 EG 024351 V3.0 020622 “ “
V5.1 T09 Skand. 024401 V3.0 020622 “ “
As of V6.0 with KC V2.2
V6.0 T11 024860 V3.0 020622 “ “
V6.2 024861 V3.0 020622 “ “

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Table of the EMC – MONITOR program versions and all the available combinations
CP1 Video Monitor

Prog. Version Text Version Id. No Prog. Vesrion Id. No. Monochrome Color
V1.1 (1.0) T01-T03 EG 020150 V1.1 (1.0) 020131 “
V1.1 (1.0) T02 Skand 020150 V1.1 (1.0) 020131 “
V2.0 T06 EG 020151 V3.0 (2.0) 020620 “
V2.0 T06 EG 020151 V3.0 (2.0) 020621 “ “
V2.0 T07 Skand. 020152 V3.0 (2.0) 020620 “
V2.0 T07 Skand. 020152 V3.0 (2.0) 020621 “ “
V3.1 T08 EG 020155 V3.0 (2.0) 020620 “
V3.1 T08 EG 020155 V3.0 (2.0) 020621 “ “
V3.1 T09 Skand. 020156 V3.0 (2.0) 020620 “
V3.1 T09 Skand. 020156 V3.0 (2.0) 020621 “ “
V3.1-S T08 EG 020157 V3.0 (2.0) 020620 “
V3.1-S T09 Skand. 020157 V3.0 (2.0) 020621 “ “
V3.1-S T08 EG 020158 V3.0 (2.0) 020620 “
V3.1-S T09 Skand. 020158 V3.0 (2.0) 020621 “ “
CP Version no longer available = see IP2/97 =
V4.0 T08 EG 023590 V3.0 020622 “ “
V4.0 T09 Skand. 023900 V3.0 020622 “ “
V4.0-S T08 EG 023610 V3.0 020622 “ “
V4.0-S T09 Skand. 023620 V3.0 020622 “ “
V4.1 T08 EG 023591 V3.0 020622 “ “
V4.1 T09 Skand. 023601 V3.0 020622 “ ”
V4.1-S T08 EG 023611 V3.0 020622 “ “
V4.1-S T09 Skand. 023621 V3.0 020622 “ “
V4.2 T08 EG 023592 V3.0 020622 “ “
V4.2 T09 Skand. 023602 V3.0 020622 “ “
V4.2-S T08 EG 023612 V3.0 020622 “ “
V4.2-S T09 Skand. 023622 V3.0 020622 “ “
V4.3 T11A EG 023593 V3.0 020622 “ “
V4.3 T11B Skand. 023603 V3.0 020622 “ “
V4.3-S T11A EG 023613 V3.0 020622 “ “
V4.3-S T11B Skand. 023623 V3.0 020622 “ “
V4.4 T12A EG 023594 V3.0 020662 “ “
V4.4 T12B Skand. 023604 V3.0 020662 “ “
As of V5.0 with PMS Card and KC V2.1
V5.0 T08 024330 V3.0 020622 “ “
V5.0-S T08 024340 V3.0 020622 “ “
V5.1 T08 EG 024331 V3.0 020622 “ “
V5.1 T09 Skand. 024411 V3.0 020622 “ “
V5.1-S T08 EG 024341 V3.0 020622 “ “
V5.1-S T09 Skand. 024321 V3.0 020622 “ “
As of V6.0 with KC V2.2
V6.0 T11 024840 V3.0 020622 “ “
V6.0-S T11 024850 V3.0 020622 “ “
V6.2 024841 V3.0 020622 “ “

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Extensions to Monitor machines (Drupa 90 version)
1. Program extension to V5.0 or V5.1
2. PMS System
As of machine 155 EM – EMC Monitor no. 6021001 (April 1990) the program V5.0 was employed
on CP1. Shortly after that, this program was modified to version V5.1. This change involves the
boards CP1, KC, BTM and PI.
EM – Monitor
CP1 Video
V5.0 T08 024350 V3.0 020622 Monochrome Color
EMC – Monitor
CP1 Video
V5.0-S T08 024341 V3.0 020622 Monochrome Color
V5.0-S T05 ->T09 024421 V3.0 020622 Monochrome Color
This modification of program versions V5.0 and V5.1 cause the following changes to the
previously used control boards.
1.1 The PI board, id. No. 024080, is no longer equipped with a slot for interchangeable memories,
because the program memories are now integrated into the CP1 computer board. All the other
functions on the PI board remain unchanged. For service purposes, the former PI boards can
be used too.
1.2 Keyboard controller KC, id. No. 023830 is a new development. Apart from the well known
features of these boards a new slot for the PMS card has been installed. The additional
red colored LED V22 which is designated R/W (Read/Write) indicates the reading and
writing functions of the PMS card. The mechanics of the KC has also been changed. –
see BTM –
1.3 The BTM control unit, id. No. 023810 (EMC), 024360 (EM), has also been modified and can
therefore no longer be used on machines with the older program versions. The complete
keypad has been displaced about 10 mm downward in order to have enough space for 10
additional function keys, which are not used at the moment, however.
Please note! The BT – DNF has also been mechanically changed.
2. The PMS card, POLAR Memory System, id. No. 228243, is a check-card size memory card
offered as an optional unit. This PMS card is a 3V Lithium battery-backed RAM which has capacity
of 99 programs. This memory serves to transfer programs from machine to machine, from computer
to machine or simply to store cutting programs.
It is no main memory comparable to our RSP interchangeable memory.
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Excerpt from IP2/97
Reduction of program versions for EM/EMC Monitor machines
The CP1 boards listed below, which are meant for machines without PMS card, replace the boards with
software versions V 1.1 t o V 3.1-S, inclusive . The reduction of variants ac hieved in this way makes stock
keeping easier and organization clearer. For any conversion, please observe the compatibility of the Video
card you use in connection with the corresponding program status of the CP1.
If the machine still contains a European standard size video PC Board, remember to remove the guide tie
in the CU before installing the new video board (double European standard size). Please return any
defective or replaced boards to our spare parts department.
Current program versions of CP1 boards

( which replace the versions V1 . 1 to V3 . 1 - S inclusively)
Machine Board Version Id. No. Board Id. No. Comment

Text
EMC CP1 V4.4 T12a 023594 Video 2 020622 Color, Monochrome
EMC CP1 V4.4 T12b 023604 Video 2 020622 Color, Monochrome
EM CP1 V4.4 T12a 023774 Video 2 020622 Color, Monochrome
EM CP1 V4.4 T12b 023784 Video 2 020622 Color, Monochrome
Text T12a for program version V4.4 Text T12b for program version V4.4
1 = GERMAN D 1 = GERMAN D
2 = ENGLISH GB 2 = ENGLISH GB
3 = FRENCH F 3 = FRENCH F
4 = SPANISH E 4 = TURKISH TR
5 = ITALIAN I 5 = DANISH DK
6 = PORTUGESE P 6 = NORDWEGIAN N
7 = DUTCH NL 7 = SWEDISH S
8 = JAPANISE J 8 = FINNISH SF
As of now all the CP1 boards which are returned for repair will be retrofitted to program status
V4.4 or more recent, or replaced by new boards of the relevant program status. If a new graphics
card is
also necessary for the conversion of the machine at the customer’s please order this
card separately.

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Power supply
Power Module (PM)
The Power Module accommodates the power supply components for the machine control system and
includes the main distribution board (PMD), fuse board (PMF), control transformer and rectifier component
(PMR). The three-phase lines from the main and (automatic) star-delta switch are protected by three fuses
of 10 amps, each, in the main distributor. Behind these fuses, the backgauge drive motor, blower motor,
fluorescent lamp for table illumination, and the control transformer are connected.
The transformer is switched on via relay K304 on the main distributor. The relay is controlled by the green
“Control voltage ON“ button on the right top of the front panel when the (automatic) star-delta switch is
changed over to the “ delta“ position. When the machine is switched off by pressing the button – 2 9 2 – “ 0 “
relay K304 drops out and turns the transformer off.
(see circuit diagram 115 EMC 3102 a/c circuit 2 - 24 as well as 45 - 49)
Adaptation of the control voltage to varying mains voltages can be carried out on the main distributor.
The primary circuit of the transformer can be operated with voltages of 180V to 260 V which are supplied
either between two phases (220 V position) or between a phase and the neutral (380 V position).

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The control transformer generates the following voltages on the secondary windings:
Secondary voltage Application PFM Fuse

~32 VAC P S plug-in board +5 V, +24 V and +12 V F1 = 6.3 A
~11.5 VAC +9 V f or cont rol unit and keyboard co mputer F2 = 4.0 A
~12.5 VAC Cutting-line indicator lamp F3 = 4.0 A
~42 VAC 42 VDC for magnets (except for Y27 + Y33) F4 = 6,3 A
~12.5 VAC Cutting-line indicator lamp F5 = 4.0 A
~15 VAC Not assigned F6
~42 VAC 42 V cont rol volt age for contactors of backgauge drive mo tor F7 = 1.0 A
~20 VAC Not assigned F8
~30 VAC Fixomat
~15 VAC Fixomat
The 1 Amp fine-wire fuse for the 32 VAC blower motors is accommodated on the CUM unit (top right).
Control voltages
In order to operate the control system the Power Supply (PS) board generates stabilized DC voltages
of +5 V, +12 V and +24 V, respectively.
The Keyboard Computer (KC) and control unit (BTM) module is supplied with a voltage of +9 VDC from
the Power Module (PM).
The solenoid valves and lifting magnets in the machine are energized through an unstabilized DC
voltage of +42 V (except Y27 and Y33).
At the measuring socket on the bottom edge of the SK board you can measure the stabilized voltage
of +42 VDC.
In unloaded condition the value is approximately 55 VDC

(consequently, no magnet is energized)

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Description of plug-in boards

Power Supply (PS)
The Power Supply board (PS) provides three stabilized voltages:
+5 VDC, Tolerance: 5.08 - 5.12 V

+12 VDC, Tolerance: 11.4 - 12.6 V
+24 VDC, Tolerance: 23.7 - 24.3 V
Each voltage is assigned a green LED and a measuring socket on the front of the board.
These voltages are not adjustable.
In order to ensure a defined start of the control system after the control voltage has been connected
the board generates a reset signal, which can be indicated by the red LED V3.
The LED is usually off during operation. It only lights briefly when the control voltage is turned on and off.

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Central Processor (CP1)
The 16-bit computer board determines all the machine cycles and operating features through the EPROM-
stored processor program. The remaining plug-in cards are connected to the computer by means of two
separate bus systems. The front side is equipped with four connectors for serial interfaces, where the
keyboard computer, the printer and the peripheral units can be connected.
Battery-buffered RAM components serve to store the variable machine data (e.g. brake afterrun,
most recent program and step numbers, cut counter, etc.). The relevant lithium-type 3.5 V battery is
accommodated on the board. The battery voltage must not drop below 3.0 V.
When the pushbutton on the front side of the board is pressed, a computer reset is triggered which is
similar to turning off/on the control voltage again. While the machine is in operation the LED in this button is
lit and indicates that the microprocessor on the board is working. On those boards which are delivered as
spare parts the lithium battery is taken off to prevent any unnecessary discharge.
As of program version V5.0 (see page 07) the program memories A and B are integrated into the
CP1 board! It has a capacity of 99 programs with 1528 memory locations per memory.

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Positioning Interface (PI)
The Positioning Interface board includes all the assembly groups, which are required for the
backgauge movement:
- counter chain for forward and backward pulses of the linear measuring system
- preselector for setting the reference position
- inputs of the single-hand control switches (S10, S14, S18)
- inputs of the table limit switches
- outputs of the table motor and brake lifting solenoid controls
- slots for the RSP memories (only on V1.0 to V4.4)
The S7 selection switch serves to preset the preferred language and measuring unit to be used after the
machine is turned on, for instance when the battery has been replaced and the data on the CP1 board
has been lost. The counter monitor can be connected to the three plugs A, B, C located on the PI board.
The PI boards as of id. No. 020141 are no longer furnished with these 3 plugs, because the counter
chain is integrated in a special module (Gate Array). The V16 and V17 LED’s have also been omitted.
As of CP1 Version V5.0 we employ the PI board with id. No. 024080. The slots for the interchangeable
memory have been omitted. For test purposes the board can also be employed with older CP1
versions.
Setting the preselector switch S7 (only on program versions V1.0 – V5.1)
Language
Switch No.
S7.5
Language No.
1 S7. S7.3 S7.2 S7.
German Not assigned OFF OFF OFF OFF
2 English Not assigned OFF OFF OFF ON
3 French Not assigned OFF OFF ON OFF
Not assigned OFF OFF ON ON
4
5 Not assigned OFF ON OFF OFF
Not assigned OFF ON OFF ON
6
7 Not assigned OFF ON ON OFF
8 Not assigned OFF ON ON ON
9 Not assigned ON OFF OFF OFF
10 Not assigned ON OFF OFF ON
The languages as of No. 4 are available on CP1 board depending on the text version.
Measuring system
Switch No.
Measuring system S7.6
S7.8 S7.7
Centimeter OFF OFF Not assigned
Millimeter OFF ON Not assigned
Inches ON OFF Not assigned
Sun ON ON Not assigned

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PI PLUG-IN BOARD
LED No. Color Meaning Ground State

V15 Red Lights about 0.5Sec, when reference point is overrun OFF
V16* Red* Forward counting ON/OFF*
V17* Red* Flashes during backgauge movement ON/OFF*
V18 Yellow Table limit switch, rear ON
V19 Yellow False clamp plate I (S6) OFF
V20 Yellow False clamp plate Ii (S218) OFF
V21 Yellow Fixomat active OFF
V22 Yellow Pedal actuated (S390) OFF
V23 Yellow “Forward“ Switch (S10) OFF
V24 Yellow “Reverse” Switch (S14) OFF
V25 Yellow Manual precision adjustment (S18) OFF
V26 Yellow Backgauge motor return movement OFF
V27 Red Backgauge motor fast OFF
V28 Red Spare/reserved OFF
V31 Yellow Table limit switch, front ON
V32 Red Backgauge motor is ON OFF
V33 Red Brake lifting solenoid is ON (Y17) OFF
* no longer on PI boards as of id. No. 020141yellow = input red output
Setting the selection switch S7 as of program version V6.0 (T11)
Switch No.
S7.5
Language No. S7. S7.3 S7.2 S7.
German Not assigned OFF OFF OFF OFF
1 English Not assigned OFF OFF OFF ON
2
3 French Not assigned OFF OFF ON OFF
Spanish Not assigned OFF OFF ON ON
4
5 Italian Not assigned OFF ON OFF OFF
Dutch Not assigned OFF ON OFF ON
6 Danish Not assigned OFF ON ON OFF
7 Finnish Not assigned OFF ON ON ON
8 9 Swedish Not assigned ON OFF OFF OFF
10 Norwegian Not assigned ON OFF OFF ON
11 Portuguese Not assigned ON OFF ON OFF
Japanese Not assigned ON OFF ON ON
1
Turkish Not assigned ON ON OFF OFF
1
Setup of a measuring unit (cm, mm, Inch, sun) is as described on the previous page.

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Positioning Interface (PI)

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Linear measuring system (LMS)
While the backgauge is moved the reading head of the linear measuring scale delivers 0 and 90-degree
pulses, which are then quadruplicated by the PI board. Depending on the direction in which the
backgauge moves, these pulses are counted up (return) or down (advance), respectively, in the counter
chain. By quadruplicating the pulses a measuring accuracy of one counting pulse in 0.01 mm of back
gauge travel is obtained. Every time the
reference point is overrun (approx. at the
center of the scale) a pulse loads the value
set by selector switches S1…S6 into the
counting chain (reference measurement). A
basic condition for perfect counting pulses is
a proper calibration of the measuring sledge
with regard to glass ruler, i.e. the scanning
grating in the measuring slide must be
parallel to the counting bar on the glass ruler.
These counting bars are not visible with the
naked eye, because they are 0.02 mm wide.
The distance between two counting bars is
also 0.02 mm. You can merely perceive the
bars as gray colored stripes, about 8 mm
high, on the glass ruler.
The mechanical adjustment of the measuring

slide and the electrical setting of the counting
signals are carried out in the factory using
special instruments when the linear
measuring scales are produced. T he
mechanical setting of the reading head in the
measuring system at the customer’s can be
made with the adjusting set, id. No. 020364.
This adjusting set allows to check if the

reading head delivers counting pulses or if it
really detects the reference point. You can
also measure if the setting pulse for the
counter chain is located in the center of the
reference signal. This is indicated by the bar
graph on the adjusting instrument. You can
readjust the pulse by means of the adjusting
screw at the measuring slide, which will also
readjust the parallel position of grid plate and
glass ruler.
The reference testing instrument id. No. 023798 is available for verifying the deviations
(also temporary deviations) upon backgauge positioning, as well as for inspecting the ruler
cable.

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Linear measuring system (LMS)

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Interchangeable memory
The interchangeable memory is a PC Board fully-enclosed in a plastic housing which contains two
battery-backed RAM components (memories). The memory capacity of 1,664 records can be distributed
to 99 programs. Depending on the location on the PI board the memory indicates either A or B on the
screen as an identification. At the factory the battery is designed for an operation of a min. 5 years. The
3.5 V Lithium battery is accessible after both housing covers have been opened. It can be replaced with
the control voltage switched on.
Battery voltage should not fall below 3.0 V, because program data may be lost otherwise.
Motor Control Unit (MCM unit)
The change-pole three-phase current backgauge motor is switched by three contactors

located on the MCM unit:
K11M active = high number of revolutions

K12M active = advance direction of rotation
K15M active = reverse direction of rotation
During the backgauge movement the brake

lifting solenoid of the backgauge motor is
energized. In order to ensure a fast lifting of the
brake the 24 VDC coil of the brake lifting
solenoid is briefly supplied with a voltage of
approximately 50 V from a capacitor (C1).
The control signals for the contactors and the

brake lifting solenoid are generated on the
Positioning Interface board and supplied to the
MCM unit via a flat-belt cable.
Backgauge motor and blower motor are
protected against overload and short circuit by
one overload switch, each.
* Auxiliary relay
K12 = Backgauge motor ON

K15 = Backgauge motor Forward/Backward
K11 = Backgauge motor Fast/Slow

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Cutting circuit (SK)
The fail-safe sequence of a cutting cycle is ensured by the cutting circuit board. During the clamping and
cutting processes, the hardware logic of this board and the software contained in the Central Processor
generate instructions controlling the activation of the hydraulic valves and the safety bolt. The air supply of
the machine table is controlled with the help of one relay, each, for the solenoid valves of the front and rear
table air supply. The light barrier (identical infrared light barrier as on the EMC II machines) only interferes
with the cutting circuit. The light barrier amplifier receives the test signal (LST) from board SK and supplies
the enabling signals LS and LS.
For testing purposes the LS – Simulator test plug, id. No. 019548 can be used instead of the
light barrier.
For servicing the control system can be operated without cutting circuit board. In this case, the features
“clamping “, “cut“, “mechanical cutting -line indicator “ and “connect air supply “ are not availa ble. After
switching on, the message “enable cut buttons“ is displayed on the screen. Both the manual and automatic
control of the backgauge drive (and the operating function via keyboard) are possible.
At the socket on the bottom edge of the board you can measure the unstabilized voltage of +42 VDC.
If no solenoid is energized the measuring value is approximately 55 VDC. In order to monitor the
control conditions the cutting circuit board is equipped with LED’s on its front side:
LED No. Color Meaning Ground State

V83 Red Lights about 0.5 Sec, when reference point is overrun OFF
V84 Red Forward counting OFF
V85 Red Flashes during backgauge movement OFF
V86 Red Table limit switch, rear ON
V87 Red False clamp plate I (S6) OFF
V88 Red False clamp plate Ii (S218) OFF
V89 Red Fixomat active OFF
V71 Yellow Pedal actuated (S390) ON
V72 Yellow “Forward“ Switch (S10) OFF
V73 Yellow “Reverse” Switch (S14) ON
V74 Yellow Manual precision adjustment (S18) ON
V75 Yellow Backgauge motor return movement OFF
V76 Yellow Backgauge motor fast OFF
V77 Yellow Spare/reserved OFF
V78 Yellow Spare/reserved ON
V79 Yellow Spare/reserved ON
V80 Yellow Table limit switch, front OFF
V81 Yellow Backgauge motor is ON OFF
V82 Yellow Brake lifting solenoid is ON (Y17) OFF

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Cutting circuit board (SK)

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Cutting circuit with two-channel hydraulic system
For machine models 92, 115, 137, 155, 176 EM/EMC Monitor
which are sold in Germany and England.
The following components are new (Feb. 1990)
Electrical System
1. Control transformer BV6328 id. No. 228755.

2. 4 proximity switches 0.8 mm.
3. MHY control PC Board with housing.
4. Adapters of plugs CU 2, 6, 9, 15 on plug 431.
5. 2 connecting cables with plugs for solenoid valves Y27a and Y33a.
Mechanical system
1. Hydraulic control unit with 2 additional re-circulating ball solenoid valves Y27a and Y33a
2. 4 cam disks.
3. 1 holding sheet metal for the proximity switches.
The 4 cam plates are numbered from 1 – 4 and connected by pins. They can be adjusted a max. 2 0 mm,
as before, for setting the top dead center. The proximity switches are also numbered from 1 – 4 and
mounted at a distance of 0.6 – 0.8 mm from the cam plate.
Knife upstroke control
The MHY control PC Board which is mounted in a housing on the rear of the machine frame is furnished
with a voltage stabilization of its own: for 24 VDC voltages for the proximity switches and 5 VDC for the
electronic components as well as relays K1 and K2. The 24 VAC supply voltage for the MHY control board
is supplied by the control transformer via plugs X1, 14, 15. It is protected with 1Amp by a circuit fuse. The
individual signals of the four proximity switches are evaluated in two electronic modules. Via 2 transistors
the K1 and K2 relays for the knife upstroke control are activated.
Control of the two-channel hydraulic system
Parallel to the solenoid valves Y27 and Y33 (adapter plug No. 6) two relays K3 and K4 are also activated.
By means of their normally open contacts the solenoid valves Y27a and Y33a are energized with a
s e p a r a t e v o l t a g e s u p p l y o f 4 2 V D C C U 2 . 14 a n d 15.
The relays K3 and K4 for controlling the additional solenoid valves Y27a and Y33a are positively driven
and self-monitoring.
The NC contact of relay K3 is looped into the circuit of the safety bolt resting position B. SB E ( plug CU 9 . 8 ) .
The NC contact of relay K4 is looped into the circuit of cut button S28a NC contacts (plug CU 15.8).
In case of a self monitoring error the following error messages are displayed:
Release cut buttons (Relay K4 of MHY)

Unlock mechanical lock (Relay K3 of MHY)

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LIGHT BARRIER (LS)
The light barrier works with invisible infrared light of a wavelength of 960 nm and consists of the following
parts: transmitters, receivers and the light barrier PC Board (LS). The light barrier PC Board is
accommodated in the left-hand light barrier housing, where the receivers are also located, while the
transmitters are in the right-hand light-barrier housing. For the voltage supply the LS board has a +12 VDC
stabilization, which is operated at +24 VDC.
The t ransmit t ing diodes generat e li ght pulses at a cycle of approximately 1000Hz. Three transmitting
diodes, each, are connected in series, with the transmitting diodes 1, 3 and 5 on one hand and 2, 4 and 6
on the other hand are working in anti-phase. The current running through the transmitting diodes can be
checked with the help of 2 red-colored LED’s (V13 fir transmitters 1, 3, 5 and V15 for transmitters 2, 4, 6)
on the LS board. The voltage drop to be measured for each transmitting diode is approximately 1 VDC.
Any error occurring at the oscillator output, which is in phase opposition will be indicated by the LED V1
lighting up. On the receiver side the incoming light pulses are converted into electric signals by photo pin
diodes and then digitized by downstream amplifiers. The decoding circuitry has a double setup and
works in parallel.
The connection compares receiver signals with regard to their frequency and phase positions with the
corresponding t ransmit t er signals and generates an output level in case of conformity. The two output
levels are inversed so that short circuits in the outputs can be detected. The output levels are indicated by
2 light emitting diodes visible from outside (V10 red and V8 green). In order to localize any channel that
has been broken down the LS board is equipped with LED’s (V2 – V7), which are glowing slightly with
normal operation , but are brightly illuminated when a channel fails.
The light barrier housings are adjusted at the factory, which ensures that a reproducible installation is
ensured during assembly. However, should it be necessary to readjust one of the rays, the PC Boards of
the transmitting and receiving diodes can be shifted to adjust the focus precisely, after the fastening screws
have been loosened. In the proper position the AC voltage at the receiver diode reaches a maximum value.
The minimum value is 150 mV AC, measured at the individual receiver diodes.
The correct adjustment of the light barrier can be checked with the service jumper inserted on board LS,
either by measuring the voltage at each of the receivers or by triggering various cuts.
Before each clamping process or knife movement the Central Processor (CP1) initiates a light-barrier test
where the transmitting diodes are briefly switched off. Within 40 ms the light barrier must respond with the
condition “interrupted“. Otherwise, the light barrier test is considered as not successful and the relevant
error is shown on the display.
Caution! The red LED V10 is part of the safety circuit of the light barrier.
In case of a defect of the LED the green LED V8 will also go out,
which causes the cutting and clamping functions to be locked.
The two LED’s V17 and V18 are off when the light barrier is working perfectly. They monitor the two output
levels of the light barrier to the SK board. If these levels are not inversed the LED’s will light up. In this
case, both clamping and cutting functions are locked.

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Video Controller (VID)
The Video Controller (VID) plug-in board generates the signals for the horizontal and vertical
synchronization required to activate the monitor, and the video signal for the screen content. These pieces
of information for the monochrome monitor are combined to a composite video signal on the board and
supplied to the monitor through a 75-ohm coaxial cable. The two BNC plugs on the front side of the board
can be used alternatively.
For the color monitor, the Video Controller board supplies a video signal in the form of an RGB signal
which is supplied at the 9-pin socket on the front side of the board. A cable and the relevant plugs connect
it to the monitor. A color monitor can only be operated if the necessary Video Controller plug-in board is
available (see section 1.1).
During machine operation the Video Controller receives the necessary information about the screen
content from the Central Processor (CP1). When the control voltage is switched on the Video Controller
generates a test pattern, which consists of horizontal and vertical lines and is displayed when the Central
Processor (CP1) does not supply any information (for example: CP1 not plugged in).
The test pattern is required for setting the monitor. On Video Controller boards equipped with the red
colored LED V5 the diode must light when the control voltage is ON. When it goes out, the Video Controller
must have suffered a defect, which locks the Central Processor and therefore all the functions.
Monitor (CRT)
All the monitors used with Polar machines are operated at a service voltage of 220 V , 50 - 60 Hz. The
voltage supply is ensured by the Power Module and taken from the primary circuit of the control
transf ormer . A t rouble f ree f unct io n of the monitors is only ensured with the proper voltage supply.
Therefore, make sure to adjust the machine to the available mains voltage during the machine assembly.
An insufficient voltage may result in fluctuating images. The adjustment is made by re-plugging the jumper
(200 – 260 V) on the fuse board in the Power Module.
In the case of a failure or defect, the monitor should be dismantled from the housing and replaced. You
should not perform a correction of the setting, because some of the components remain at high potential.
Furthermore, a modified setting may result in an inadmissible release of X-radiation.
The monitors are hung up and connected to the housing by means of vibration absorbers.
The rear of the housing has a turning knob for adjusting the brightness.
Keyboard Computer (KC) and control unit (BTM)
The Keyboard Computer (KC) monitors all the keys of the control unit (BTM) and the switches for
distortion, label correction and retarding of the cutting cycle. Any actuation of the controls is reported
serially to the Central Processor. The internal supply voltage of +5.10 V is generated from the supplied
voltage of +9 V and can be checked with the green LED and two measuring sockets.
With the potentiometer located beneath the measuring sockets the value of +5.1 V can
be readjusted, if necessary.

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During operation the red V19 LED “computer activated“ is flashing every second. The keyboard
computer has a self-testing routine for troubleshooting.
(see Service Information)
The KC and BTM assemblies are not required for carrying out the basic functions of the
machine. For service purposes the control system can be run without this assembly.

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Timer board (CLK)
The CLK (Clock) board contains a timer module. When the control voltage is turned off this module
is supplied from a 2.4 V Lithium battery.
The CLK board is connected to the CP1 board through the iP bus. It is required as a time base for
generating the production report. The TP1 test point is only required to calibrate the clock frequency for the
timer module. On those boards, which are delivered as spare parts, the lithium battery is taken off to
prevent any unnecessary discharge. The CLK board is not essential for the functioning of the machine
control system.
For service purposes the control system can be operated without this board and consequently, without
the time. In this case, the production report feature is not possible.
On cutting machines equipped with the optimized high-speed backgauge the Servo board is
plugged in instead of the CLK board. The Servo board includes the timer module and carries
out the functions of the CLK board.
PMS CARD
The PMS Card, POLAR Memory System, id. No. 228243, is a check-card size memory card offered as
an optional unit. This PMS card is a 3 V Lithium battery-backed RAM which has a capacity of 99
programs.
This memory serves as a data medium for cutting programs from machine to machine, from Compucut
to machine or simply for saving and storing recurrent cutting programs. The PMS Card is no main
memory comparable with our RSP interchangeable memory.
New knife change as an optional equipment

POLAR EM/EMC - Monitor 92/115/137/155
As of POLAR 137 EM/EMC - Monitor, machine serial No. 6041201, the new knife change system
is available as an optional equipment.
The following components are new:
1. Front panel
2. Knife bar
3. Knife
4. Knife screws
5. Knife wrench
6. Knife adjusting cam at the con-rod
7. Automatic stop at bottom dead center

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All the actions for the new knife change are carried out from the front
side. Both the knife bar and con-rod adjustments are made in the
factory and must not be changed. The knife has to be installed and
removed precisely according to the enclosed operating instructions.
When adjusting the knife, draw it slightly nearer with the screws, then
tighten the knife support screws (left side first).
The knife must not tilt upward (see sketch).
If the knife does not cut the material perfectly after some cuts have been made, it may be adjusted
deeper at t he knif e adjust ing cam by mean s of a knife wrench. Before doing so, push the cam lock
upward (see sketch). The knife adjusting cam has 9 catch positions and must be reset to “0“ with every
knife change (turn counterclockwise).
When the cam lock is pushed upward, no cut can be performed.

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Part list No. 1
Title Position Function

KC Frame Keyboard Computer
CRT Frame VDU
CU Frame Control Unit Motherboard
SK CU Cutting Circuit Plug-in board
CP1 CU Central Processor Plug-in board
PI CU Positioning Interface Plug-in board
VID CU Video Controller Plug-in Board
PS CU + 5/ 12/ 24 V D C P o w e r S u p p l y P l u g - i n board
UEB CU Cutting Circuit Transformer board
RSP CU RAM Memory
LS Frame Light Barrier board
LSV Frame Light Barrier Transmitter Distributor board
LMS Table Linear Measuring System
MCM Frame Backgauge Motor Control
MHS Cable duct Knife Upstroke Control
PM Frame Power Supply Unit
PMD PM Power Supply Unit – Distributor boar d
PMF PM P ower S upply Unit – Fuse board
PMR PM Power Supply Unit – Rectifier board
SDS Frame Automatic Star-Delta Starter
A1 Frame Mains Supply
B. SBA Frame Cont rol Sensor “electro -me ch. non-repeat device out of action“
B. SBE Frame Control Sensor “el.-mech. non-repeat device in locking position“
BTM. S1 BTM B CD S witch: clamping time adjustment
BTM. S2 BTM Shaft Encoder: Distortion
BTM. S3 BTM Shaft Encoder: Label Correction
B29 Frame Proximity Switch “Clamp at Top“
CP1.G1 CP1 Lithium Battery - voltage source for data saving
CP1.S1 CP1 Reset button
CRT.F CRT 2.5 A Fuse
CRT.R1 CRT Brightness Control Potentiometer
CU.F1 CU 1 A Fuse for ventilators (M.V a/b)
E39 Frame Fluorescent Lamp with starter
E42a Frame Lamp for optical cutting-line indicator
E42b Frame Lamp for optical cutting-line indicator
K1M SDS Mains contactor
K3M SDS Star contactor
K5M SDS Delta contactor
K3T SDS Time-delay relay

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Part list No. 2

K11 MCM Relay: Table motor “High Speed“
K12 MCM Relay: Motor ON
K15 MCM Relay: Return stroke
K11M MCM Contactor: Table motor “High Speed“
K12M MCM Contactor: Advance movement
K15M MCM Contactor: Return stroke
K22 a/b MHS Auxiliary relay for cutting and clamping
K304 PMD Relay “Control voltage ON“
KC.B1 KC Signal horn
KC.S1 KC Key: Self test
L38 Frame Fluorescent lamp ballast
M3 Frame Main motor
M17 Table Backgauge motor
M93 Table Blower motor
M.Va CU Ventilator
M.Vb CU Ventilator
PM.C1 PM Filter capacitor for +42 VDC
PM.C2 PM Filter capacitor for +9 VDC
PM.C3 PM Filter capacitor for +5/12/24 VDC
PM.V1 PM Rectifier for +42 VDC
PM.V2 PM Rectifier for +9 VDC
PM.V3 PM Rectifier for +5/12/24 VDC
PMD.Z1 PMD Mains filter
PMD.F1 PMD Main fuses 3 x 10 A
PI.K1 PI S wit ching contact with backgauge motor brake
PI.S7 PI S wit ches : “Language /measuring unit “ pr esetting
PMF.F1 PMF Fuse 6.3 A for 32 VAC
PMF.F2 PMF Fuse 4 A for 11.5 VAC
PMF.F4 PMF Fuse 6.3 A for 40 VAC
PMF.F6 PMF Fuse 1 A for 15 VAC
PI.S1 PI Coding switch for reference position 1/100 mm
PI.S2 PI Coding switch for reference position 1/10 mm
PI.S3 PI Coding switch for reference position mm
PI.S4 PI Coding switch for reference position cm
PI.S5 PI Coding switch for reference position dm
PI.S6 PI Coding switch for reference position m
PS.F1 PS Fuse 4 A for +24 VDC
PS.F2 PS Fuse 1.4 A for +12 VDC
Q2 Frame Main switch
Q92 MCM O verload switch for blower motor (M9 3)
Q96 MCM Overload switch for backgauge motor (M17)

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Part list No. 3

RSP.G1 RSP A ccumulator - voltage source for data saving
S6 Pressure Clamp False clamp plate contact
S7 Table Switches: Changeover of advance speed “Fast-Slow“
S8 Table Limit switch with false clamp inserted
S9 Table Limit switch “Advance Movement“
S10 Table S witch “Backgauge brake OFF/Advance movement ON“
S13 Table “Reverse“ Limit switch
S14 Table “Reverse“ button
S18 Table Switch “backgauge brake OFF“
S22a Gearbox Limit switch “Cutting and Clamping“
S22b Gearbox Limit switch “Cutting and Clamping“
S28a Table B ut t on “Cutting and Clamp ing“
S28b Table B ut t on “Cutting and Clamp ing“
S41 Frame Change-over switch for cutting-line indicator
S87 Table Button “Air supply ON“
S217a Table Limit switch “Advance movement with first additional false clamp plate“
S217b Table Limit switch “Advance movement with second addit . f alse clamp plate“
S218 Pressure Clamp False clamp plate contact with additional narrow false clamp
S292 Frame Button “Drive and control voltage ON“
S309 Frame Pedal switch (clamp)
S340 Frame Switch for knife change
S360a/b Table “F orward “ Limit switch with inserted false cla mp plates and Fixomat
S390 Table P e d a l s w i t c h ( a d v a n c e m ovement)
SDS.F2 SDS Protective motor relay for main motor
SK.K1 SK Relay : A ctivation of electro -mechanical non-repeat device (Y.SB)
SK.K2 SK Relay: Front/Rear table air supply (Y94)
SK.K3 SK Relay: Air supply “Front Table“ (Y94a)
Tr PM Transformer
V35 Frame Light barrier: Light Emitting Diodes (LED) IR transmitter
V36 Frame Light barrier: Photo Diodes Receiver
Y17 Table Brake lifting solenoid for backgauge motor brake
Y27 Frame S olenoid valve for clamping
Y33 Frame Solenoid valve for cutting
Y94 Table Solenoid for air table
Y94a Table Solenoid valve for front table air supp ly
Y315 Frame Solenoid for cone valve
YSB Frame Solenoid for electro-mechanical non-repeat device

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EM/EMC - MONITOR
SERVICE INFORMATION
LIST OF ERROR MESSAGES

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Reference material regarding error messages and

status information on EM/EMC Monitor machines
Compilation and description of all significant error messages on EM(C) Monitor

machines As of version 1.0 up to version 6.0, inclusively
List of screen texts
ALL DATA UNREADABLE: DELETE 42 CLAMPING TIME INTERRUPTED 47

EJECTOR RUN 42 PROGRAM DATA ERROR 48
AUTOTRIM TABLE OPEN 42 PROGRAM NOT READABLE 48
BRK - ERROR 42 PROGRAM ERROR: DELETE 48
BSY - ERROR 0, 1, 2, 3, 4, 5 42 PROGRAM SAVED 48
SWIVEL BACKGAUGE LIMIT POS. 42 SOURCE PROGRAM UNREADABLE 48
SWIVEL BACKGAUGE NO REACTION 43 SOURCE MEMORY UNREADABLE 49
DUSTERROR 43 GO TO REFERENCE POSITION 49
JOGGING MARK 43 RE-READING ERROR: DELETE 49
BACKGAUGE LIMIT 43 BACKGAUGE MOVEMENT LOCKED 50
EPROM – ERROR 43 DELETE STEP 50
ERROR 43 STEP UNREADABLE 50
WRONG STEP NUMBER 43 STEP ERROR: DELETE 50
WRONG PROGRAM NUMBER 43 CUTTING CIRCUIT ERROR 50
WRONG PROGRAM ARCHITECTURE 44 CUTTING CIRCUIT INTERRUPTED 50
FIXOMAT END-OF-TRAVEL IND. MISSING 44 CUT BUTTON DEFECTIVE 50
FIXOMAT LIMIT SWITCH DEFECTIVE 44 ENABLE CUT BUTTONS 50
FIXOMAT FUNCTION LOCKED 44 CUTTING LOCKED 50
ERROR KNIFE TIME PRESETTING 44 NUMBER OF CUTS HAS BEEN REACHED 51
SECONDARY OPERATION 44 SIDE GAUGE LOWERED 51
I/O - BUS ERROR 45 SIDE GAUGE TIME ERROR 51
NO PULSES FROM RULER 45 SIDE GAUGE NO LIM. POSITION SIGNAL 51
NO MEASUREMENT AVAILABLE 45 MEMORY CONTENTS UNREADABLE 51
LIGHT BARRIER INTERRUPTED 45 MEMORY AREA UNREADABLE 51
LIGHT BARRIER ERROR 45 MEMORY ERROR DELETE 51
MANUAL BACKGAUGE MOVEMENT 45 MEMORY NOT PLUGGED IN 51
POSITION NOT REACHED 45 SAFETY BOLT RETRACTED 52
MEASUREMENT TOO BIG/SMALL 46 SAFETY BOLT LOCKED 52
KNIFE-WIND UP 46 SAFETY BOLT MONITORING DEFECTIVE 52
KNIFE CHANGE 46 NON-RETURN VALVE 42V ERROR 52
TILTING BACKGAUGE LIMIT 46 SPV - ERROR 52
TILTING BACKGAUGE NO REACTION 46 STAT. CUTTING CIRCUIT ERROR 52
TURN LABELS 46 TXT - ERROR 53
OPTION NOT AVAILABLE 46 PMS CARD INVALID 53
PMS CARD COMPL. UNREADABLE 46 OBSERVE MAINTENANCE INTERVAL 53
PMS CARD WITH DATA ERRORS 47 INADMISSIBLE VALUE 53
PMS CARD NOT INSERTED 47 OVERFLOW 53
PMS CARD RE-READING ERROR 47 TARGET PROGRAM DATA ERROR 53
PMS - ERROR 47 ADDITIONAL FUNCTION INADMISSIBLE 53
AUTOMATIC POSITIONING ACTIVE 47 TARGET MEMORY NOT READABLE 54
CLAMP NOT AT BOTTOM POS. 47

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CAUSE REMEDY
ALL DATA Program memory area (“A“ or “B“) Up to V4.4:
UNREADABLE or PMS card no longer accessible. Relevant memory or memory area must be
= DELETE = The data is no longer complete or is cleared completely. Battery of removable
incorrect. The affected data areas memory (RSP) must be checked, Replace
can only be cleared, in order to removable memory, PI board check PS
make a new storage. board
As of V5.0:
Please note! This message can be Replace. Check voltage supply to
displayed when the machine is Completely clear the relevant memory or
switched on (put into service) and/or memory area. When first using the memory
the first use of a PMS card, because area A or B - check battery of CP1 board,
the “A“ or “B“ memories or the PMS replace CP1 board. Check voltage supply
card have not been initialized by a to PS board. When using the PMS Card,
deleting procedure. check the PMS Card, its battery, PMS Card
slot.
EJECTOR RUN Machine control system has initiated If there is no backgauge movement in spite
backgauge movement for of the message: check overload switches
programmedejector run. for motors, MCM unit with contactors, check
voltage supply.
AUTOTRIM AUTOTRIM table is not closed, or Close AUTOTRIM table

TABLE during closing procedure the light Check position of S1 on SFM board,
OPEN barrier was interrupted! replace SFM board, check limit switch S3 6 4
and relevant cabling.
BRK - ERROR Error in data exchange between CP Check voltage supply of PS board, Check
1 board and control panel. voltage supply +9 V for KC, Check
Occurs on machines with V5.0 and compatibility of CP1 board and KC, correct,
V5.1 if necessary.
sporadically and without any
further meaning when switched on.
BSY - Error which has been detected by Check voltage supply of PS board, verify
ERROR 0, 1, operating system of the program on operation, replace CP1 board replace KC.
2, 3, 4, 5 the CP1 board. Or by pressing the
keyboard too hard.
SWIVEL During manual readjustmen t or Check S347 and S348 limit switches and
BACKGAUGE during the automatic limit position their cabling. Check CUM. 5 1 . 6 / 3 SER. 3 0 6 ,
LIMIT POSITION positioning of the swivel the relevant SER.314 and 706 plugs.
limit switch (depending on direction) Replace DNF board, replace SER unit
has been reached.

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DISPLAY
CAUSE REMEDY
SWIVEL During manual readjustmen t or Check motor for swivel backgauge (M357),
BACKGAUGE during t he aut omat ic check potentiometer RD and rel. cabling check
NO positioning of the swivel backgauge, PM.409, SER.300, SER.301, 701, CUM.51,
REACTION there is no true change of the SER.314, SER.304 CUM.313 and 713
backgauge position to be plugs, verify setting of DNF board, replace
recognized. DNF board, replace SER unit.
DUSTERROR Data transmission error between Turn the machine off and then switch it on.
CP1 and COMPUCUT or Replace CP1 board(s), check data lines
AUTOCUT - SPS. check Compubox.
JOGGING MARK With programmed additional Check programming and operation.

function JOGGING MARK the
operator tried to make a cut.
BACKGAUGE B ackgauge has moved to active Check active table limit switch
LIMIT table limit switch relevant for this Replace PI board, check plug CUM.106
direction. Or locking adapter with (and 106a, if available).
rear-table feeding, rear-table shutoff
with light barrier or switch controlled
rear-table guarding activated.
EPROM - ERROR see “TEXT - ERROR“ see “TEXT - ERROR“
ERROR Internal error message of CP1 card: Turn the machine off and then switch it on.
ERROR1 = Error detected by OS Replace CP1 board
of the CP1 operating program.
ERROR2 = Text EPROM is
defective or plugged incorrectly
ERROR3 = Text EPROM not
compatible
WRONG STEP Invalid input of a step number under Correct your input.
NUMBER the functions STEP SELECTION &
INSERT or DELETEADDITIONAL
FUNCTIONS
WRONG A program number < 0 > or < 9 8 > Change number was input.
PROGRAM
NUMBER

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CAUSE REMEDY
WRONG Error in Eltrotact Verify program and correct architecture
PROGRAM programming.
ARCHITECTURE
FIXOMAT One of the two lay marks are in Try to go to limit position
END-OF-TRAVEL undefined position. Check S341, S342, S343, S34. switches
INDICATOR and relevant cabling
MISSING Plugs CUM.307 and 707 must be checked
Replace DNF board Check Fixomat motors
M345 and M346.
FIXOMAT LIMIT For one or both lay marks two limit Check S341, S342, S343, S34. limit
SWITCH position switches are simultaneously switches and their cabling
DEFECTIVE signaled as being actuated. Check plugs CUM.307 and 707, replace
DNF board.
FIXOMAT Function Backgauge too close to Check switches S360, (S360qand S360b),
FUNCTION clamp for carrying out the Fixornat Check CUM. 106, replace PI board (S360
LOCKED function activated).
ERROR This error message is shown when Check P2 circuit and relevant activation,
KNIFE - TIME a cut is performed & a max. preset verify solenoid valve Y330, replace SHM
PRESETTING time of 3 Sec has been exceeded in board and SK board.
(as of V 6.0) the activated movement of the knife
from TDC to BDC.
SECONDARY This mode of operation is set Go to reference position

OPERATION automatically once the machine is Check LMS and relevant cabling , chec k
turned on, if the process GO TO backgauge drive unit
REFERENCE POSITION, owing to Replace PI board.
errors in the area of drive unit /LMS
(or if reference position on PI board
was incorrectly preset) could not be
performed correctly.
The “SECONDARY OPERATION“
can also be turned on in the menu
“GO TOREFERENCE POSITION“
by pressing the “C“ button (in
Servo data image – letter „A“).

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CAUSE REMEDY
I/O - BUS ERROR Input and output signals of I/ O – bus Turn the machine off and then switch it on,
system cannot be read correctly. verify voltage supply; if necessary, plug-in
boards CP1, SK, 5FM, SHM, DNF, PDR, or
CUM must be replaced.
NO PULSES During mot orized backgauge Check MC unit and contactors 11, 12 and
FROM adjustment no pulses from linear 15, check backgauge and relevant
RULER measuring system have been activation, LMS and relevant cabling must
recorded. be checked, replace PI board.
NO Positioning (2 times equals key) Verify operation

MEASUREMENT available was initiated without
AVAILABLE indication of measurement.
Or automatic advance function was
activated without program
measurement.
LIGHT Cut was abort ed becaus e light Remove all obstacles from the optical path
BARRIER barrier light barrier was interrupted. of the light barrier and finish the cut. Check
INTERRUPTED the LS board, replace, if necessary. Check
light barrier, relevant cabling and setting.
Check CUM.4, CUM.5, LS.600, LS.601.and
LSV.602 plugs, verify voltage supply +24V,
check S1 and S2 of tiltable rear-table
guard. Replace SK board.
LIGHT Error in light barrier self testing Check setting of LS, check transmitter and
BARRIER receiver diodes
ERROR Verify + 2 4 V voltage supply, replace LS
card
MANUAL Machine cont rol system has Check switches S1 0 , S 1 4 and S1 8 , check
BACKGAUGE movement initiated backgauge overload switch for motor, check MCM unit
MOVEMENT movement or backgauge motor with contactors.
brake was manually electrically Verify voltage supply.
activated.
POSITION Difference between required Check lubrication of backgauge afterrun

NOT nominal position and actual Brake and slowdown travel must be re-
REACHED after a positioning procedure. determined via function “GO TO
REFERENCE POSITION“. Backgauge
drive unit and relevant activation must be
checked, Check backgauge motor brake, if
necessary clean and re-adjust it. Check
LMS and relevant cabling. Replace PI
board With Servo – check zero point
adjustment of ESR device.

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CAUSE REMEDY
MEASUREMENT Measurement input does not Check switch 13

TOO coincide with machine size Have reference pos. read in again.
BIG/SMALL
KNIFE-WIND UP After switching the machine ON the Switch the machine off and manually turn
knife is not in the upper resting the knife back to the TDC by turning the
position. flywheel.
CAUTION!
Observe safety information.
Check P2 circuit, check gearbox limit switch
KNIFE CHANGE Knife change function was switched Check switch S340
on.
TILTING During adjustment of tilting Check limit switches S349 and S350 and
BACKGAUGE backgauge the direction related limit relevant cabling. Verify setting of DNF
LIMIT position switch has been reached. board, Check plugs CUM.51, SER.304,
SER.314 and 704 Replace DNF board,
replace SER unit
TILTING During manual readjustmen t or Check motor for tilting backgauge drive
BACKGAUGE NO during the automatic positioning of M358, check potentiometer RN & relevant
REACTION the tilting backgauge, no true cabling, Check plugs CUM.312, 712,
change of the tilting backgauge PM.409, SER.300, SER.302, 702,
position has been detected. CUM.51, and SER.314 Verify setting of
DNF board, replace SER unit, replace
DNF board.
TURN LABELS In an Eltrotact program cycle
sequence it was detected that the
last cut size is smaller than the
minimum size to be approached.
OPTION A n opt ional f unct ion was called Check if corresponding function is switched
NOT which either is not available or does on the control boards.
AVAILABLE not exist at all. Replace the relevant control board.
PMS CARD All the data on the PMS CARD Set ON/OFF switch on PMS Card to ON.
COMPLETLY cannot be read. Please note! Verify if PMS Card is correctly plugged,
UNREADABLE T his message can be displayed Initialize board by a complete clearing,
when a PMS CARD is used for the Verify battery voltage of PMS Card.
first time because this PMS CARD
has not yet been initialized by a
deleting process.

DOC REF:
(Reproducti
DISPLAY
CAUSE REMEDY
PMS CARD WITH Part of the data stored on PMS Card Check, if PMS Card has been correctly
DATA ERRORS (individual programs and/or steps) inserted.
cannot be read. Delete programs or steps and enter again.
Check battery voltage of PMS Card,
replace PMS Card.
PMS CARD Insert PMS Card into relevant slot Check, if PMS Card has been correctly
NOT on control unit. inserted, replace BTM, replace KC.
INSERTED
PMS CARD RE- Malfunction when writing on PMS Check, if PMS Card has been correctly
READING Card. After check of recorded inserted. Set ON/OFF switch of PMS Card
ERROR information an inequality was to ON. Switch any existing write protection
detected. switch on PMS Card off. Check battery
voltage of PMS Card, replace PMS Card,
replace BTM, replace KC.
PMS - ERROR Data transmission error between C h e c k d a t a l i n e b e t w e e n KC and CP1.

PMS Card and CP1 board. Check, if PMS Card has been correctly
Please note! Error message inserted. Set ON/OFF switch of PMS Card
“PMS - ERROR 4“ can also be to ON position. Switch off any existing write
issued as a sequence error of “BRK protection switch on PMS Card, Check
- ERROR“ . battery voltage of PMS Card, Replace PMS
Card, Replace BTM, replace KC.
AUTOMATIC Machine control system has initiated Remedy, if there is no backgauge active
POSITIONING backgauge movement. movement in spite of display: Check
ACTIVE overload switch f. motor, check MCM unit
with contactors, verify voltage supply.
CLAMP NOT Operating information in KNIFE at Operate cutting line indicator; if necessary,
AT BOTTOM bottom CHANGE mode, if operator verify activation, check B29.
POSITION tries to cut without having lowered Replace SK board
the clamp.
CLAMPING Between cut initiation and knife Verify setting of clamping time delay in
TIME movement the cutting or clamping BTM.
INTERRUPTED procedure was aborted by operator.

DOC REF:
(Reproducti
DISPLAY
CAUSE REMEDY
PROGRAM All the data in a program in the Remedy up to V4.4:

DATA memory areas of the machine („A “ Completely delete the relevant program and
ERROR or „B“) or a program of the PMS input again. Check battery of removable
PROGRAM card cannot be read. memory (RSP), Program error Replace
NOT removable memory, replace PI board.
READABLE Check voltage supply to PS board, replace
PROGRAM PS board.
ERROR: DELETE Remedy as of V5.0: Completely delete the
relevant program and input again. When
using the A or B memory area, check CP1
board and battery. Check voltage supply of
PS board, replace PS board.
When using the PMS Card, check the PMS
Card, its battery, PMS-Cardslot, replace
BTM, replace KC.
PROGRAM Someone attempted to change the Un-protect program under “Program

SAVED program or delete a protected Information“
program.
SOURCE While using the functions Remedy up to V4.4:

PROGRAM “COPY PROGRAMS“, Delete relevant program completely and
UNREADABLE “COPY ONTO PMS CARD“ and re-input. Check battery of removable
“LOAD FROM PMS CARD“ data of memory, replace removable memory
the source program could be read. replace PI board, Check voltage supply of
Remedy as of V5.0:
Completely delete the relevant program and
input again. Use of memory area A or B –
Check battery of CP1 board, replace CP1
board, Verify voltage supply to PS board,
replace PS board. When using the PMS -
Card, verify the PMS Card, its battery, the
PMS Cardslot, replace BTM, replace KC.
SOURCE While using the functions Remedy up to V4.4: Clear the relevant
MEMORY “COPY PROGRAMS“, memory or memory area completely. Check
UNREADABLE “COPY ONTO PMS CARD“ and battery of removable memory, Replace
V4.4 “LOAD FROM PMS CARD“ the removable memory, replace PI board,
source memory cannot be read. check voltage supply of PS board, replace
PS board.

DOC REF:
(Reproducti
DISPLAY
CAUSE REMEDY
SOURCE While using the functions Remedy up to V5.0: Relevant memory or
MEMORY “COPY PROGRAMS“, and memory area must be cleared
UNREADABLE “COPY ONTO PMS CARD“ and completely. Use of memory area A or B -
V5.0 “LOAD FROM PMS CARD“ the Check battery of CP1 board, replace CP1
source memory cannot be read. board. Power supply check PS board,
replace PS. When using the PMS Card,
check the PMS Card, its battery, PMS Card
slot, replace BTM, replace KC.
GO TO When machine is switched on the Check battery on CP1 board,

REFERENCE parameters required for normal Replace CP1 board, check switches S10,
POSITION operation, such as the latest S14 and S18. Check keys in BTM for
backgauge position, last brake activating the backgauge movement.
afterrun value, length of slowdown
travel etc. are not available. This
message is output when: The
machine had been switched off
during act ivat ed backgauge
movement. A machine is switched
on for the first time,
(commissioning). The CP1 board
had been replaced. Function has
been selected in PRESET
F UNCT I O N menu. I f this status
occurs wit hout any of the above
mentioned conditions the saving of
data might be disturbed when the
machine is switched off.
RE-READING Malf unct ion when writing on Check battery of CP1 board, replace CP1
ERROR: DELETE machine program memory (“A“ or board. Check, if PMS CARD has been
“B“) or onto PMS Card. correctly inserted. Set ON/OFF switch of
When checking the written PMS Card to ON position, Any existing
information a discrepancy was write protection switch on PMS Card must
detected. be turned off, Verify battery voltage of PMS
Card, replace PMS Card, replace BTM,
replace KC.

DOC REF:
(Reproducti
DISPLAY
CAUSE REMEDY
BACKGAUGE Via SFM board the backgauge Locking during rear-table loading
MOVEMENT movement was locked. Check rear-table protectio n with LS or
LOCKED switch controlled rear-table guarding. On
machines with SERVO: check backgauge
drive and relevant activation, LMS and
relevant cabling, replace PI board.
DELETE STEP In a program of the machine Delete steps and store again, re-input the
STEP memories “A“ or “B“ the data of one entire program, if necessary. Check battery
UNREADABLE or more steps are no longer of CP1 board, Replace CP1 board. Check
STEP readable. The relevant steps are battery of removable memory, replace
ERROR: marked in the menus “CUTTING removable memory, replace PI board.
DELETE PROGRAM“ and “PROGRAM
INFORMATION“ by representing
their contents with lines “-—“ .
CUTTING SK board detects error in cutting Check cutting circuit (LED’s) replace SK
CIRCUIT circuit cycle. board.
ERROR
CUTTING No agreement between software - Check if knife is in TDC, if necessary, wind
CIRCUIT activation and safety control channel the knife up. Turn machine off and turn the
INTERRUPTED of SK board. knife manually to its top dead center by
Sporadic occurrence of this turning the flywheel.
message does not indicate a PLEASE NOTE!
malfunction in any case. Observe safety information. Check gearbox
limit switches. Check magnet Y.SB,
replace SK board.
CUT For one or both cut buttons the input Check cut button and replace, if necessary
BUTTON signals for make and break contacts (see IP1/91 section 2.20.00e)
DEFECTIVE are simultaneously recognized as Check CUM.15 plug
being activated. Replace SK board.
ENABLE Indicates that at least one cut button Check cut button and replace, if necessary
CUT is pressed. (see IP1/91 section 2.20.00e),
BUTTONS Check plug CUM.15,
Replace SK board (Rel. K4 fr. HMY)
CUTTING Attempted execution of cut with Check Autotrim function and waste removal
LOCKED activated signal “cut is blocked“ of stroke, check backgauge movement,
SFM board. Replace SFM board. Replace PI board.

DOC REF:
(Reproducti
DISPLAY
CAUSE REMEDY
NUMBER OF Cut counter has reached preset Cut counter preselection in survey (8) must
CUTS HAS BEEN value. be readjusted or switched off.
REACHED
SIDE Attempted cut with activated signal Move side gauge up,
GAUGE “side gauge lowered“ SHM board. Replace SHM board.
LOWERED Automatic knife is switched off or set
back to the step “prepared“ .
SIDE Side gauge limit position is not Check side gauge limit switch
GAUGE TIME reached within admissible time. Check side gauge for mechanical stiffness,
ERROR replace SHM board, check locking of rear
table loading.
SIDE GAUGE W hen machine is switched on at Move side gauge up or down. Check side
NO LIMIT least one side gauge is in undefined gauge limit switch, Check switch positions
POSITION SIGNAL position. on SHM board, replace SHM board, check
locking of rear table loading.
MEMORY None of the data in a memory area Remedy up to V4.4:

CONTENTS of the machine (“A“ or “B“) or in a Relevant memory or memory area must be
UNREADABLE memory area of the PMS card can cleared completely. Check battery of
MEMORY be read. removable memory, replace removable
AREA memory, if necessary, PI board. Check
UNREADABLE Please note! voltage supply of PS board, replace PS
MEMORY This message may be shown (put board.
ERROR into service) and/or on first use of a Remedy as of V5.0:
DELETE PMS card because the “A“ or “B“ Relevant memory or memory area must be
memories or the PMS card has not cleared completely. When memory area A
been initialized by a deleting or B are used. Check battery of CP1 board,
procedure. replace CP1 board. Check power supply to
PS board, replace PS board. When using
the PMS Card, check the PMS Card, its
battery, PMS Cardslot. Replace BTM and
KC, if necessary.
MEMORY O n versions up t o V 4.3 or old er Plug the removable memory into “A“ or “B“
NOT selected removable memory is not slot on PI board. Replace removable
PLUGGED IN plugged onto the PI board. memory, replace PI board.

DOC REF:
(Reproducti
DISPLAY
CAUSE REMEDY
MECHANICAL This message indicates that home Check if knife is in TDC, wind the knife up,
LOCK UNLOCKED position of machine (knife in top if necessary. Turn machine off and turn the
dead center or machine just turned knife manually to its top dead center by
on) the mechanical lock (or the turning the flywheel.
safety rocker switch) for the knife PLEASE NOTE!
bar is not in the safety position. Observe safety information.
Check smooth operation of mechanical lock
or safety rocker switch).
Check magnet Y.SB, check switch B.SBE,
Check plugs 44 and CUM.9 , replace SK
board. (Rel. K3 of MHY)
MECHANICAL Before the cut is started the Check smooth operation of mechanical lock
LOCK mechanical lock (or safety rocker or safety rocker switch).
LOCKED switch) does not reach proximity Check magnet Y.SB, check switch B. SBA,
switch B.SBA or not in a timely Check plugs 44 and CUM. Replace SK
manner, or leaves t he B.SBA board.
proximity switch during the cutting
procedure.
MECHANICAL The mechanical lock (or safety Check smooth operation of mechanical lock
LOCK rocker switch) is in an undefined (or safety rocker switch).
MONITORING state of malfunction. Both proximity Check magnet Y.SB, check switches
DEFECTIVE switches B.SBE and B.SBA B.SBE and B.SBA. Check plugs 44 and
signalize simultaneously the CUM 9, Replace SK board.
positions “knife bar released“ and
“knife bar locked“ .
NON-RETURN On one activated non-return valve Verify voltage supply (measuring point
VALVE 42V Y 3 1 5 no voltage of + 4 2 V is SK.P1 Nom. +50 V to +55 V) solenoid valve
ERROR supplied to switching line of non- 315 (ohms) must be checked, plug CUM.6
return valve. and magnet. Replace SK board.
SPV - ERROR Internal error message for Switch machine off and on
memory management of CP1 Verify voltage supply, Replace CP1 board.
board.
STATIC No agreement between software Remove any obstacles from the optical path
CUTTING activation and safety control channel of the LS and finish the cutting process.
CIRCUIT ERROR of SK board. Verify voltage supply, Replace SK board.
Sporadic occurrence of this
message does not necessarily
indicate a malfunction in any case.
On V5.1 and V4.2 this message
occurs if an interrupted cut is
continued while the light barrier is
interrupted.

DOC REF:
(Reproducti
DISPLAY
CAUSE REMEDY
TXT - ERROR After turning the machine on Replace CP 1 board.
erroneous identification of text
EPROM on CP1 board.
PMS - The PMS card plugged into the Use original PMS Card.
CARD control unit cannot be identified. Check, if PMS Card has been inserted
INVALID correctly, replace PMS Card.
OBSERVE Counter for service has exceeded Reset the counter for service under survey
MAINTENANCE interval 100,000. of functions (7).
INTERVAL
INADMISSIBLE During the programming an Verify programming.
VALUE inadmissible input was detected
(e.g. total cuts - 0).
OVERFLOW When using the calculating function,

an overflow of the arithmetic
memory was caused.
TARGET While using the functions Remedy up to V4.4:

PROGRAM DATA “COPY PROGRAMS“, Completely delete the relevant program and
ERROR “COPY ONTO PMS CARD“ and input again, check battery of removable
„LOAD FROM PMS CARD“ all the memory, replace removable memory,
data from the target program replace PI board, check voltage supply of
could not be read. PS board, replace PS board.
Remedy as of V5.0:
Completely delete the relevant program and
input again. When using the memory areas
A or B - check battery of CP1 board,
replace CP1 board.
Check voltage supply to PS board, replace
PS board. When using the PMS Card,
check the PMS Card, its battery, PMS Card
slot, replace BTM, replace KC.
ADDITIONAL Inadmissible additional function was Verify operation.

FUNCTION called up.
INADMISSIBLE

DOC REF:
(Reproducti
DISPLAY
CAUSE REMEDY
TARGET While using the functions Remedy up to V4.4:
MEMORY NOT “COPY PROGRAMS“, Completely delete the relevant program and
READABLE “COPY ONTO PMS CARD“ and input again. Check battery of removable
„LOAD FROM PMS CARD“ no data memory, replace removable memory,
of the target memory can be read. replace P 1 board , Check voltage supply of
Remedy as of V5.0:
Clear the relevant program completely and
input again. When using the A or B memory
area – check battery of CP1 board, replace
CP1 board. Verify voltage supply to PS
board. When using the PMS Card, check
the PMS Card, its battery, check the PMS
Cardslot, replace BTM, replace KC.

DOC REF:
(Reproducti
SERVICE INFORMATION
Since the I/O bus boards are switched in parallel (see block diagram, page 3) a defective board may affect
machine functions, which are controlled by another board. By removing the boards one by one the
defective board can be localized.
1. All machine functions except for the monitor display are possible without the Video (VID)
plug- inboard.
2. The functions of backgauge movement, display and control panel are possible without the
cuttingcircuit (SK) board plugged in. The message “enable cut buttons“ is displayed on the screen.
3. All the machine function except for the operating elements on the control panel are possible
without the assembly of Keyboard Computer (KC) and control unit (BTM)
4. Self-test of the Keyboard Computer (KC) and control unit (BTM) assembly: With the
machine switched off, remove the plug-in connection of the X500 serial interface from the KC
board. (see drawing on page 26)
Make a short-circuit bridge by plugging the test connector onto X500.

The test plug is on the right side of plug X500.
Switch the machine on.

Activate self-test by pressing the key S1 on the KC board.
The red LED “Test okay“ V20 is lit when the self-test of the Keyboard Computer has
been performed without errors.
When one of the keys is actuated or released or when the rotary switch is adjusted on board
BTM you hear an acoustic signal.
While a key is being actuated the LED V20 „Test okay“ is out.
Turn the machine off and re-establish the X500 connection.
Put test plug back to the position of rest.

The test plug does not affect the machine control system.
5. When the machine is switched off with the backgauge brake electrically activated or the last
backgauge position stored no longer available, for instance because the battery on the CP1
boardhas been replaced, the machine has to be moved to reference position after it has been
switched on.
Once the control voltage has been connected the monitor displays the prompt = go to reference
position = actuate hand wheel.

DOC REF:
(Reproducti
When searching the reference position the control system determines the following parameters:
End of table (Distance between cutting line and rake when the rear table limit switch is
reached).
Slow down travel (Distance between the switchover point from the high to the low backgauge motor
speed on one hand and reaching the low speed on the other hand). The computer
multiplies this distance by the factor of 1.5 in order to compensate for fluctuations.
Brake afterrun (Distance between the shut-off point of the brake lifting solenoid and the
backgauge at standstill).
Caution! If the backgauge movement has been modified, for instance by
- replacement or readjustment of the brake lifting solenoid
- replacement of the backgauge motor
- modification of the reference position
- replacement or readjustment of the spindle nuts
- readjustment of sledge guide
- change of position of the rear table limit switch
- replacement of the CP1 board,
the control system has to determine these parameters again while the machine is switched off with
the brake electrically activated. When the machine is turned on for searching the reference
position, activate the advance or return stroke.
6. The front and rear limit stops of the backgauge movement is exclusively determined by the
positions of the table limit switches (hardware shutoff). Adjust the limit switch in such a way that the
smallest attainable cut size of the 9 2 , 1 1 5 and 1 3 7 machines is 2 5 mm, and on the 1 5 5 and 1 7 6
machines 35
m
The remaining limit switches must be set to ensure that the backgauge motor is switched off at
least 10 mm before the mechanical stop at the false clamp plate or at the end of the table is
reached.
7. When the “Service“ function has been selected from the Survey of functions, enter the code number
8520 and confirm with the “actual position” key.
The screen displays: (as of program version V2.0)
(1) Machine data

(2) Change machine data

DOC REF:
(Reproducti
By input of the relevant number one of the two sub-menus is branched.
(1) Machine data EM(C) - Monitor V...

Language presetting E.g.: German
Measuring unit presetting E.g.: cm
Text - EPROM Version
Software Version V...
Brake afterrun E.g.: 0.034 cm
Slow down travel E.g.: 2.154 cm
End of table E.g.: 116.83 cm
(2) Change machine data EM(C) - Monitor V...
(1) Accuracy allowance (max. permissible tolerance in a

positioning procedure. The factory setting
is 0.008 cm. Possible values: 0.008 – 0.1
cm)
(2) Total cut counter E.g.: 88888888
(3) Switch-off display correction (if the max. admissible tolerance is not exceeded
in a positioning process the actual position
display will be rounded up or down.)
(3a) Switch-on display correction (In this case the “actual position“ display is
not rounded.)
(4) Print service report
(5) Input/output control (shows the conditions of all essential input and
output signals of the control system. Those
signals which are not in their ground level state
are inverted. The features “clamping“, “cut“,
“mechanical cutting-line indicator“ and “manual
backgauge movement“ are available.)
(6) Set reference position (indication to support the setting of the

reference position)
( 7 ) Remark
8. The functioning of the VID board and the screen can be verified by turning on the control voltage
without the CP1 board installed in the machine. The screen shows a test pattern which consists of
horizontal and vertical lines. This test pattern can be used for setting the image orientation, height,
width and linearity. The controllers for adjusting these parameters are located on the PC Board
inside the screen housing. Please learn the positions of the controls from an adhesive label on the
tube bulb.

DOC REF:
(Reproducti
9. In order to retain the data when the control system is switched off the interchangeable memory
and the CP1 board are provided with (3.5 V) batteries. These batteries should be replaced every
five years or when the battery voltage falls below 3 Volts.
The battery of the interchangeable memory should be changed with the memory plugged in
and the control voltage switched on, because the stored program data will otherwise be lost. It
is also possible to copy the program data into another memory before replacing the battery.
The CLK board also carries a battery (2.4 V), which supplies the timer module when the machine
is switched off.
Secondary operation
The secondary operation makes the manual backgauge movement as well as the clamping and
cutting functions possible. The monitor continues to display all the data except for the “actual position“.
Via the keys on the control unit the individual menus can be selected (also the “Service“ function).
There are two ways to get to the secondary operation
1. When searching the reference position and no reference point is detected because of a defective
measuring system, a defective connecting cable for the measuring system or a defective PI plug-
in board, the system will automatically switch to secondary operation after the third attempt.
The “ program data“ image is shown, and instead of the “actual position“ the text
“secondary operation“ is displayed.
2. If the “Program Data“ button is pressed before or after searching the reference position, the
system switches instantly over to secondary operation.
Please note! When the optional equipment “optimized high-speed backgauge“ is available the
backgauge movement may be locked when the measuring system has suffered a failure. In this case,
no search of the reference position is possible. In this case, press the “ program data“ key to start
the secondary operation.
Deactivating automatic knife functions

(see IP1/97)
POLAR EM/EMC - Monitor machines
1. Plug the jumper (MS) onto the cutting circuit board (SK).
2. Install board SFM unless it is already installed.
3. Insert a jumper on the CU, from plug 57, pin 5 to pin 9.
4. Separate the strip conductor for the „automatic knife ON“ key from the control unit.
Please remember to note down the changes on the customer’s circuit diagram

DOC REF:
(Reproducti
Printer interface
All Monitor machines are prepared for connecting a printer. This connection is made by a serialinterface
on the front side of the CP1 (X5) board.
Polar Machines are designed to work with Epson printers equipped with serial
interfaces.Thenecessary connecting cable is included in the toolbox of every Monitor machine upon
delivery.
The following list shows the required devices:
Epson Matrix printer, such as: FX - 8 7 0 Purchase no. C 0 9 4 0 1 1

Serial interface: Purchase no. 8143
Pull/push tractor Purchase no. C806382
Sheet feeder Purchase no. C800202
The above listed components can be purchased from Epson.
Printer cable id. No. 020328 (Polar)
The Epson printers must be adjusted for program versions V1.0, V1.1, V2.0, V3.1(S), V4.0(S) and
V4.1(S), respectively, in the following way:
Installation at EPSON FX800 printer
1. Printer Board: Switch position (DIP - Switch)
DIP-Switch SW: 1 = PIN 1 = OFF DIP-Switch SW: 2 = PIN 1 = OFF

1 = PIN 2 = OFF 2 = PIN 2 = ON
1 = PIN 3 = ON 2 = PIN 3 = ON
1 = PIN 4 = OFF 2 = PIN 4 = ON
1 = PIN 5 = ON
1 = PIN 6 = ON
1 = PIN 7 = ON
1 = PIN 8 = ON
Please remember to note down the changes on the customer’s circuit diagram

DOC REF:
(Reproducti
2. Serial - Interface Board: switch positions
DIP - Switch SW: 1 = PIN1 = OFF Program Version V2.0.0, V3.1.0(S)

Program Version V4.0(S), V4.1(S)
1 = PIN1 = ON Program Version V1.1/V1.0
1 = PIN2 = ON
1 = PIN3 = ON
1 = PIN4 = ON
1 = PIN5 = ON
1 = PIN6 =
OFF 1 = PIN7
= OFF 1 =
PIN8 = OFF
DIP - Switch SW: 2 = PIN1 = ON

2 = PIN2 = ON
2 = PIN3 = OFF
2 = PIN4 = OFF
2 = PIN5 = OFF
2 = PIN6 = OFF
3. Serial - Interface Board: Set jumpers
Jumper: 1 = OFF
2 = OFF
3 = OFF
4 = OFF
5 = ON
6 = OFF
8A = ON
8B = OFF
X = ON
F = OFF
CL = ON
RS = OFF

DOC REF:
(Reproducti
Change of software versions according to IP
CP1 IP EMC EM SERVO

CP1 V1.1 020150
CP1 V2.0 T08 ab 86 IP4/86 020152 020930
CP1 V3.1 T08 ab 88 IP4/87 023888 023892 023890
From V4 . 0 with Graphics and with VID 3 . 0 , 0 2 0 6 2 2
CP1 V4.0 T08 ab 88 IP2/89 023590 023802 023804
CP1 V4.1 T08 ab 89 IP2/89 023501 023771 023611
From V4 . 0 with PMS Board and KC V2 . 1 , 0 2 0 8 3 0
CP1 V5.0 T08 ab 90 IP1/90 024330 024350 024340
CP1 V5.1 T08 ab 90 IP2/90 024331 024351 024341
V 4 . 2 with operation like V5 . 0 but without PMS Board
Replaced V4.0 and V4.1
CP1 V4.2 T08 ab 90 IP2/90 023592 023772 023612
From V6.0 with Menu Display and KC V2.2, 020832
CP1 V6.0 T11 ab 91 IP2/91 024840 024860 024850
Replaced V4.0 to V4.2
CP1 V4.3 T11 ab 94 IP1/94 024841 024841 Like EMC
Replaced V4.0 to V4.3
CP1 V4.4 T12A ab 9 4 IP1/94 023594 023774 Like EMC

DOC REF:
(Reproducti
Compatibility of the Video – CP1 and KC boards
Video
V1.0 V2.0 V3.0 V3.0 V3.0
020131 020132 020620 020621 020622
CP1 1* 3* 1* 3* 1* 3* 2* 4* 2* 4* 5* KC
V1.1 x x 185
V2.0 x x 185
V3.1 x x 185
V4.0 From V4.0 with Graphics x 185
V4.1 x 185
V5.0 From V5.0 with PMS Board x V2.1
V5.1 x V2.1
V4.2 Like V5.0 but without PMS Board x 185
V6.0 From V6.0 with Menu Display x V2.2
V4.3 Like V6.0 but without PMS Board x 185
V6.2 Knife Circuit Time/Error Memory x V2.2
V4.4 x 185
Explanation of Video Cards
1 * = Half Size, 2 * = Double Size, 3 * = Monochrome, 4 * = Mono Color, 5 * = Graphics
CP1 V4.2 Replaces V4.0 to V4.1

Same software as V5.0, but meant for machines without PMS Card
CP1 V4.3 Replaces V4 . 0 to V4 . 2

CP1 V 4.4 Replaces V4.0 to V4.3



Polar 191030 em Emc Mon Technical Training

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PRAF MICROCOMPUTER TECHNOLOGIES LTD. P.O.B.

7209, Holon 5817101, Israel

Setup of Control Unit

Description of Plug-in Boards

List of Error Messages – Service Information

PRAF Microcomputer Technologies Ltd. Confidential Company Property.

Monitor control unit ......................................................................................................................... 3

PRAF Microcomputer Technologies Ltd. Confidential Company Property.

Control Panel Monitor

PRAF Microcomputer Technologies Ltd. Confidential Company Property.

Arrangement of plug-in cards in the CU

PRAF Microcomputer Technologies Ltd. Confidential Company Property.

Setup of control unit

Block diagram of EM/EMC - Monitor

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Control components and their use

Title Application Machine type

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Program Versions and their use

CP1 Video Monitor

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CP1 Video Monitor

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Extensions to Monitor machines (Drupa 90 version)

1. Program extension to V5.0 or V5.1

Excerpt from IP2/97

Reduction of program versions for EM/EMC Monitor machines

Current program versions of CP1 boards

Machine Board Version Id. No. Board Id. No. Comment

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Secondary voltage Application PFM Fuse

In unloaded condition the value is approximately 55 VDC

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Description of plug-in boards

The Power Supply board (PS) provides three stabilized voltages:

+5 VDC, Tolerance: 5.08 - 5.12 V

These voltages are not adjustable.

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Central Processor (CP1)

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Positioning Interface (PI)

Setting the preselector switch S7 (only on program versions V1.0 – V5.1)

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LED No. Color Meaning Ground State

* no longer on PI boards as of id. No. 020141yellow = input red output

Setting the selection switch S7 as of program version V6.0 (T11)

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Positioning Interface (PI)

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Linear measuring system (LMS)

The mechanical adjustment of the measuring

This adjusting set allows to check if the

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Linear measuring system (LMS)

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Motor Control Unit (MCM unit)

The change-pole three-phase current backgauge motor is switched by three contactors

K11M active = high number of revolutions

During the backgauge movement the brake

The control signals for the contactors and the

K12 = Backgauge motor ON

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