ED_99gb3 / 18.02.

2000

Technical Training

POLAR
Machines
78 S, E, ES, ED
92 - 176 S, E, ED

basic course

Imprint: File: ED_99gb3.pdf / first edition: 14.02.1995

Use: all machines S, E, ES and ED
Writer: Bernd Schlensog / Klaus Meiselbach
Remark: see latest changes
Pages: 83+1

1 Accompanying documentation
18.02.2000 / ED_99gb3

Table of contents

Keyboard 78 S, 78 E, 78 ES and 92 - 176 S, E, ED ..................................................4

Control keys ...............................................................................................................5
Multi-function-keys - V1.4 .........................................................................................6
Measurements Polar 78 - 176 ...................................................................................7
Technical Data ...........................................................................................................8
rear and front elevation ............................................................................................ 9
Main switch, main drive unit .................................................................................. 10
Voltage Supply ......................................................................................................... 11
Power module 78 ES ............................................................................................... 12
Main drive 78 E ........................................................................................................ 13
Main drive 78 ES with neutral................................................................................. 14
Main drive 78 ES without neutral ........................................................................... 15
Main drive 78 ED without neutral ........................................................................... 16
Main drive 78 ED without neutral USA / CSA ........................................................ 17
Main drive 92............................................................................................................ 18
Main drive 92 beginning with 6911001 .................................................................. 19
Main drive 92 USA/CSA beginning with 6911001 ................................................. 20
Main drive 115 with Kimodul .................................................................................. 21
Main drive 115 - 176 with star-delta-switch ........................................................... 22
Main drive 115 - 176 with star-delta-switch without neutral ................................ 23
Main drive 115 - 176 with star-delta-switch without neutral USA / CSA ............. 24
Power modul 78 E, 78 ED and 92 - 176 with K304 ................................................ 25
Power modul 78 E, 78 ED and 92 - 176 without K304 .......................................... 26
Power modul 78 ES ................................................................................................. 27
Power Supply 95 (PS95) ......................................................................................... 28
Structure of Controls .............................................................................................. 29
Block diagram POLAR 92 - 176 E, ED (and 78 ED) ............................................... 29
Block diagram POLAR 78 E, 78 ES ........................................................................ 29
Control unit with extention 1 for Polar 78 - 176 S, E and ED .............................. 30
Control unit Polar 78 ES ......................................................................................... 31
Central Processor CP ............................................................................................. 32
Software-Version ..................................................................................................... 33
DIP - Switch SW2 and SW3 at CP .......................................................................... 34
Text variants (text 1 to text 8) for program version V 1.4.0.................................. 35
Backgauge Drive Positioning (SAP) ...................................................................... 36
Reference point ....................................................................................................... 38
Reference run .......................................................................................................... 38
Backgauge Drive Unit with Frequency Converter ................................................ 38
Frequency Converter Lenze 8200 .......................................................................... 39
Operating and adjustment instructions for LENZE converter 8200 .................... 39
Error messages issued by the frequency converter ............................................ 42
Block Diagram of Backgauge Drive by Frequency Converter ............................. 43

Accompanying documentation 2
 ED_99gb3 / 18.02.2000

Backgauge start after cut and Function of S390 .................................................. 44

Diagram SAP and backgauge positioning 78 - 176 S/E/ED ................................. 45
Cutting Circuit (SK 95) ............................................................................................ 46
Knife Upstroke Control (MHS 95) ........................................................................... 46
Cutting circuit .......................................................................................................... 48
Cutting operation .................................................................................................... 49
Light Barrier (LS 95) ................................................................................................ 50
Block diagram Cutting circuit ................................................................................ 51
Diagram SK95 and Cutting circuit 78 - 176 S, E, ES, ED ..................................... 52
Hydraulic System 92 -176 S, E, ED ........................................................................ 53
Control units ............................................................................................................ 54
P1 - Oil Flow Circuit ................................................................................................ 55
Description of functions ......................................................................................... 56
Actuation of the mechanical cutting line indicator .............................................. 56
Clamping without cut .............................................................................................. 57
Cut function ............................................................................................................. 58
Optional hydraulics ................................................................................................. 59
Bleeding the hydraulic system ............................................................................... 59
Reservoir label 2 channel hydraulics 92 -176 ....................................................... 60
Reservoir label 1 channel hydraulics 92 -176 ....................................................... 61
Hydraulic System 78 S, E, ES, ED .......................................................................... 62
Reservoir label 1 and 2 channel hydraulics 78 .................................................... 64
Graphic Controller (GC 1) ....................................................................................... 65
Keyboard Computer KC .......................................................................................... 66
Indicators, Plugs and Keys on KC ......................................................................... 67
Keyboard and Display 78 S - 137 S, 78 E, 78 ES................................................... 67
Keyboard and Display 78 ES .................................................................................. 68
Keyboard and Display "E" 92 - 176 (monchrome) ................................................ 69
Keyboard and Display "ED" 92 - 176 (color) ......................................................... 70
Service Information POLAR S, E, ED ..................................................................... 71
Technical Machine Data .......................................................................................... 72
Alter Machine Data .................................................................................................. 74
Presetting of Machine ............................................................................................. 75
Diagnosis / Test / Check ......................................................................................... 75
Error messages ....................................................................................................... 76
Backgauge position check ..................................................................................... 76
Input Output check .................................................................................................. 77
Measure clamp moving time .................................................................................. 77
Check of knife gearing ............................................................................................ 78
Trace of knife position ............................................................................................ 79
Remarks ................................................................................................................... 79
Overlook of adjustments and check values .......................................................... 80
List of LED´s ............................................................................................................ 82
Last changes of this file ......................................................................................... 84

3 Accompanying documentation
18.02.2000 / ED_99gb3

Keyboard 78 S, 78 E, 78 ES and 92 - 176 S, E, ED

until Oct. 97

since Oct. 97

Accompanying documentation 4
 ED_99gb3 / 18.02.2000

Control keys Enter

Insert; subsequent insertion of data

Automatic knife ON
Delete
Automatic knife OFF
Correction (of stored data)
Automatic ON
Key without function
Automatic OFF
Transfer key: Transfer backgauge pos.
into input field
Basic display "Program Data"
Calculator memory
Basic display "Program Information"
Memory Read
Basic display "Main Menu (Function
Survey)"
Backgauge movement: slow advance
Basic display "Program Survey"
Multi-function-key "Additional Backgauge movement: slow reverse
Functions"
Multi-function-key "Program Additional pushbutton: Backgauge fast
Functions"
Multi-functions-key "Programm - Para-
meter" (not at the moment) Cursor

Program selection
Preselection key:
Multi-function-key "External Additional "Tilting backgauge"
Functions" Preselection key:
Multi-function-key "Auxiliary Program "Swivel backgauge
Functions" Preselection key:
Fixomat / Holding-down clamp
Production report
Tilting backgauge "0 - position
Step selection
Tilting backgauge "Undercut"

Numerical keyboard Tilting backgauge "Overcut"

Swivel backgauge "0 - position"

Division
Swivel backgauge "angle correction
Multiplication left"
Swivel backgauge "angle correction
Addition right"
Holding-down clamp "Resting position"
Subtraction / Fixomat "O - position"
Holding-down clamp "Final position" /
Fixomat "sidemark"
Equal key
Holding-down clamp "Working position"
/ Fixomat "frontmark"
Clear input field Rotary knob "Cut correction"

Decimal point Rotary knob "Distortion correction"

5 Accompanying documentation
18.02.2000 / ED_99gb3

Multi-function-keys - V1.4

Page 1/2 Page 2/2

1. Automatic knife ON 1. Backgauge forward slow
2. Automatic knife OFF 2. Lay guide I
Multi-function-key 3. Clamping without cut 3. Lay guide II
4. Jogging mark 4. Swivel backgauge
5. Air front table ON 5. Tilting backgauge
6. Complete air table ON 6. Fixomat side mark guide /
7. Complete air table OFF Holding down clamp activ
8. Ejector OFF 7. Fixomat front mark guide /
Additional functions 9. Autotrim Holding down clamp passiv
8. Side gauge left down
9. Side gauges both down

Page 1/2 Page 2/2

1. Pressing time before cut 1. Smooth stop at position

Multi-function-key 2. Pressing time no cut 2. Optimization of clamp
3. Pressure force level 3. Clamp light barrier
4. Pressure force sensors 4. Smooth prepressure
5. Clamp forces 5. Highspeed cutting
6. Forward acceleration 6. Autotrim blowing air
7. Forward deceleration 7. START Autotrim blowair
Machine - Parameter
8. Advance speed 8. STOP Autotrim blowair

Manual Automatic

Multi-function-key 1. Program when cutting Program when cutting

2. Difference of positions Difference of positions
3. Set program protection 3. Set program protection
Simulation without cuts 4. Simulation without cuts
Correktion of cut position 5. Correction of cut position
Warning skip cutting 6. Warning skip cutting
Auxilary program
functions

Multi-
function- 1. Nominal position Multi-function- 1 EXT. FUNC. 1
key START
2. PE Programmable ejector key
3. LZ Label size 2 EXT. FUNC. 2 START
4. LQ Label quantity 3 EXT. FUNC. 3 START
5. TC Total cuts 4 EXT. FUNC. 4 START
6. PL Program loop
Program 7. C: Selection of comment 5 EXT. FUNC. 5 START
8. C: Input of comment External 6 EXT. FUNC. 6 START
functions 7 EXT. FUNC. 7 START
addittional
8 EXT. FUNC. 8 START
functions

Accompanying documentation 6
 Measurements Polar 78 - 176

78 92 115 137 155 176

mm/inch mm/inch mm/inch mm/inch mm/inch mm/inch

A 1980/77 61/64 2120/83 15/32 2712/106 49/64 2932/115 7/16 3410/134 1/4 3620/142 33/64
B 990/38 31/32 1060/41 47/64 1325/52 11/64 1435/56 1/2 1778/70 1883/74 9/64
C 359/13 9/64 350/13 25/32 344/13 35/64 344/13 35/64 653/25 45/64 653/25 45/64
D 631/24 27/32 710/27 61/64 981/38 5/8 1091/42 41/64 1125/44 19/64 1230/48 27/64
E 1408/55 7/16 1630/64 11/64 2151/84 11/16 2363/93 1/32 2540/100 2750/108 17/64
7

F- 120/4 23/32 200/7 7/8 200/7 7/8 200/7 7/8 200/7 7/8
G 780/30 45/64 920/36 7/32 1150/45 9/32 1370/53 15/16 1550/61 1/32 1760/69 19/64
H 600/23 5/8 600/23 5/8 750/29 17/32 750/29 17/32 1003/39 31/64 1003/39 31/64
Weight at position "1": I - 1267/49 29/32 1653/65 5/64 1873/73 47/64 2001/78 25/32 2211/873/64
78 4270 N J - 570/22 7/16 821/32 21/64 931/36 21/32 965/37 63/64 1070/42 1/8
92 6870 N
115 10000 N K 650/25 19/32 635/25 19/32 715/28 5/32 730/28 47/64 750/29 17/32 750/29 17/32
137 13730 N L 940/37 1/64 750/29 17/32 1020/40 5/32 1110/43 45/64 1160/45 43/64 980/38 37/64
155 16480 N M - 600/23 5/8 650/25 19/32 650/25 19/32 650/25 19/32 650/25 19/32
176 17660 N N - 300/11 13/16 260/10 15/64 260/10 15/64 260/10 15/64 260/10 15/64
Weight at position "2": O - 300/11 13/16 400/15 3/4 400/15 3/4 400/15 3/4 400/15 3/4
78 6620 N P - 255/10 3/64 360/14 11/64 360/14 11/64 360/14 11/64 360/14 11/64
92 8593 N Q - - - - 2010/79 9/64
115 15890 N R - 104,5/4 7/64 137,5/5 13/32 137,5/5 13/32 172,5/6 51/64 172,5/6 51/64

ED_99gb3
137 20410 N
155 23840 N S 580/22 53/64 600/23 5/8 700/27 9/16 700/27 9/16 1090/42 29/32 1090/42 29/32
Accompanying documentation

176 26450 N T 290/11 27/64 300/11 13/16 350/13 25/32 350/13 25/32 545/21 29/64 545/21 29/64
U 200/7 7/8 400/15 3/4 400/15 3/4 400/15 3/4 400/15 3/4 400/15 3/4
Weight at position "3/4": V 1975/77 3/4 2185/86 1/32 2563/100 29/32 2845/112 2981/117 23/64 3455/136 1/32

/ 18.02.2000
78 930 N
92 1620 N W - - - - - -
115 2750 N X 653/25 45/64 653/25 45/64 718/28 17/64 733/28 55/64 753/29 41/64 753/29 41/64
137 3140 N Y 900/35 7/16 900/35 7/16 900/35 7/16 900/35 7/16 900/35 7/16 900/35 7/16
155 4120 N Z 1452/57 11/64 1545/60 53/64 1660/66 23/64 1660/65 23/64 1745/68 45/64 1745/68 45/64
176 1470/5890 N
Accompanying documentation Technical Data

18.02.2000 / ED_99gb3
Polar 78 Polar 92 Polar 115 Polar 137 Polar 155 Polar 176

Cutting width 78 cm/30 11/16" 92 cm / 36 1/4" 115 cm / 45 1/4" 137 cm / 54" 155 cm / 61" 176 cm / 69 5/16"
Clamp opening 12 cm/4 11/16" 13 cm / 5 1/8" 16,5 cm / 6 1/2" 16,5 cm / 6 1/2" 16,5 cm / 6 1/2" 16,5 cm / 6 1/2"
Feed depth 78 cm/30 11/16" 92 cm / 36 1/4" 115 cm / 45 1/4" 145 cm / 57" 155 cm / 61" 200 cm / 78 3/4"
Power requirement (main drive) 3,45 kW/4,63 H.P. 4,45 kW / 5,97 H.P. 5,7 kW / 7,64 H.P. 6,6 kW / 10,46 H.P. 8,2 kW / 12,6 H.P. 8,2 kW / 12,6 H.P.
Net weight (without special equipment) 1300 kg/2867 lbs 1900 kg / 4190 lbs 3200 kg / 7055 lbs 4120 kg / 9083 lbs 4950 kg / 10913 lbs 6000 kg / 13228 lbs

Width without side tables 155 cm/61" 177 cm / 70" 233 cm / 91 3/4" 254 cm / 100" 279 cm / 109 3/4" 300 cm / 118 3/8"
with side tables 198 cm/77 11/16" 212 cm / 83 1/2" 265 cm / 104 3/16" 288 cm / 113 3/8" 355 cm / 139 3/4" 376 cm / 148 1/16"
Length 191,5 cm/75 3/8" 216 cm / 85" 254 cm / 100" 282 cm / 111 1/16" 295 cm / 116 1/8" 343 cm / 135 1/16"
Height 145 cm/57 1/16" 154 cm / 60 5/8" 165 cm / 64 15/16" 165 cm / 64 15/16" 173 cm / 68 1/8" 173 cm / 68 1/8"

Front table length 65 cm/25 9/16" 65 cm / 25 19/32" 71,5 cm / 28 1/4" 73 cm / 28 3/4" 75 cm / 29 1/2" 75 cm / 29 1/2"
Table heoght 90 cm/35 1/2" 90 cm / 35 1/2" 90 cm / 35 1/2" 90 cm / 35 1/2" 90 cm / 35 1/2" 90 cm / 35 1/2"

Clamp pressure min. 150 daN/330 lbs 150 daN* / 330 lbs 150 daN* / 330 lbs 150 daN* / 330 lbs 150 daN* / 330 lbs 150 daN* / 330 lbs
max. 3000 daN/6630 lbs3500 daN* / 7700 lbs 4500 daN* /9920 lbs 5500 daN*/ 12100lbs 6000 daN* / 13200 lbs7000 daN* / 15400 lbs
8

Knife thickness 11,75 mm/7/16" 11,7 mm / 7/16" 13,75 mm / 9/16" 13,75 mm / 9/16" 13,75 mm / 9/16" 13,75 mm / 9/16
Grinding reserve, max. 2,5 cm/1" 3 cm / 1 3/16" 6 cm / 2 3/8" 6 cm / 2 3/8" 6 cm / 2 3/8" 6 cm / 2 3/8"
Smallest cut, without false clamp, min. 2 cm/13/16" 2,5 cm / 1" 2,5 cm / 1" 2,5 cm / 1" 3,5 cm / 1 3/8" 3,5 cm / 1 3/8"
with false clamp, min. 7 cm/2 3/4" 9 cm / 3 1/2" 9,5 cm /3 3/4" 9,5 cm / 3 3/4" 12 cm / 4 23/32" 12 cm / 4 23/32"
Backgauge speed advance 0 - 20 cm/sec. 0 - 20 cm/sec. 0 - 30 cm/sec. 0 - 30 cm/sec. 0 - 30 cm/sec 0 - 30 cm/sec
Static floor load 525 daN/ 628 daN/m² / 706 daN/m² / 756 daN/m² /. 761 daN/m² / 755 daN/m² /
114 lbs/sq. ft. 131 lbs/sq.ft. 142,8 lbs/sq.ft. 153 lbs/sq.ft 154 lbs/sq.ft 153lbs/sq.ft

Specific pressure on surface 1,35 daN/cm² 1,6 daN/cm² / 1,6 daN/cm² / 2 daN/cm² / 2,4 daN/cm² / 2,65 daN/cm² /
19,9 lbs/sq. in. 23,16 lbs/sq.in. 22,7 lbs/sq.in. 28,4 lbs/sq.in. 34,3 lbs/sq.in. 37,9 lbs/sq.in.
Dynamic surcharge 20% 20% 20% 20% 20% 20%
Supply voltage 190-240V
Fusing 16A 25A 25A 35A 35A 35A
Supply voltage 340-440V
Fusing 10A 20A 20A 25A 25A 25A
Supply voltage 500-600V
Fusing 10A 20A 20A 25A 25A 25A

Attention! The wire cross section of the main power supply according to the countrys regulations. Use the same regulations for plug connectors.
Noise emission (according DIN 45635, part 27) 83 dB (A) T with 1152 cuts per hour (80% automatic operation)
77 dB (A) T with 300 cuts per hour (manual feeding)
 rear and front elevation

LS95 receiver
B340
B29 E42a/b
S218b BT
S218 E39
S6 S292
Y.SB Q2
B.SBA S41
B.SBE S28a
B341 LS95 transmitter
MHS 95 S87
S7 S28b
S8 S10
S9 S14
S217a S18
9

S217b Q92
S13 TR
S13a AC-IN,AC,DC,KAP
M17/WSK Y315
M17 Y27(Y27a)
Y17 Y33(Y33a)
SKÜ S390
M3 S309
M3/WSK PS95
Y94 & M94 GC1
XS1

ED_99gb3
CP
Accompanying documentation

SK95
SAP

/ 18.02.2000
fan 1
fan 2
18.02.2000 / ED_99gb3

Main switch, main drive unit

The machines of line 78 E and 78 ED are fitted with main switches for directly switching the main motor
on. Control voltage is started by key button S292 and auxiliary contactor K304.
The machines of line 78 ES are fitted with main switches for directly switching the main motor on.
Control voltage is automatically given by the transformer and the power supply units G1 and G2.
The machines of series 92 are also furnished with a main switch. Only after control voltage has been
switched on via S292 and auxiliary contactor of K304 closes does the soft start device activated by
relay K305 start the main motor. As soon as the „acceleration“ of the main motor has been terminated
the soft start unit switches on contactor KO which supplies the motor directly with three phases.
An auxiliary contact of KO (13-14) signals to the computer „acceleration terminated“. After that, the
machine is ready for operation. The soft start unit (KIMODUL) is a compact device which controls the
main motor start up.
The machines series 115 ... 176 are provided with a main switch and are switched on via the automatic
star- delta switch already known. Control voltage is activated by auxiliary contact 13-14 of K5M and
auxiliary relay K304 as soon as delta operation has been established. An auxiliary contact of K5M (43-
44) signals to the computer that the start-up of the main motor has been terminated.
The cutting mashines since december 1998 do not need a neutral (MP) any more, because the transformer
is supplied with two phases L1 and L3. The relais K304 an card AC-IN is no longer existing. The relais
K305, now with self holding contact in card AC-IN, is still used to activate the soft start unit (92 only). On
the card AC-IN is now a voltage stabilizer 24V D.C. to protect the soft start unit against to high operating
voltage.
The star delta combination (115 ... 176) has now contactors with 24V A.C. coils!
The mashines type 78 ES have a additional transformer (T2) when the mains is 400V ~ to supply the
power units G1, G2, T1, the frequency converter and lights with 230 V~.

Attention: New diagrams for Power on circuit without K304

View of „KIMODUL“

Torque
L1 L2 L3 PE 3 Adjustment of initial voltage

Adustment: 50Hz 60Hz

0 25 50% 75%
M(UO) 50
Attention! Possible errors!

100 75
LED ME = Motor start-up

LED MH = Upstroke terminated

ME MH
25 Ramp (start-up time)
0
Adjustment to maximum, then
R(UM) 50 adapt to machine
100 75 Minimum ramp recommended
= slow start-up
Main motor start-up approx. 15 sec.
Upstroke terminated after
T1 T2 T3 1 2 approx. 20 sec.

Accompanying documentation 10
 ED_99gb3 / 18.02.2000

Voltage Supply

The power module is composed of control

X1 X2 X3 X4
transformer and four power module boards
F3 F7
combined in one block.
The control transformer is designed in such a way F1 V8
that it can be supplied by one phase and neutral F4 F8 V9
V10
(Mp), or, by the two phases L1 and L3 if the V11
machine is supplied only by three phases and a F5 F9 V12
protective earth conductor (PE).
F2
F6 F10
Power module board AC IN (X1) comprises the
two fuses F1 and F2 (miniture circuit breakers) and
AC-IN AC DC KAP
auxiliary relay K304 for the primary supply to the
control transformer. Furthermore, the board has a
rectifier and relay K305 (soft start-up device 92).
Since january 1999 the board AC IN does no more T1
contain the relay K304. The circuit brakers F1 and
F2 are now mechanically connected to T1.
Because the transformer is now in all machines
supplied with two phases. The control voltage for
the soft start-up device (92) is stabelized to 24V
d.c. The new board AC IN without relay K304
cannot be used in older S, E and ED machines.

Power module board AC (X2) is fitted with fuse F3 for rectification and stabilization 24 Vd.c. / 8 Vd.c.
(knife upstroke control), fuse F4 with rectification 25 Vd.c., fuses F5 and F6 for 15 Va.c./30 Va.c. Fixomat.

Power module board DC (X3) is fitted with fuses F7 with rectifier (24 Vd.c. for operating unit), F8 (230
Va.c. for frequency converter and illumination), F9 (spare) and F10 with rectifier (32 Vd.c. for PS95).

Power module board KAP (X4) is composed of transformer, rectification and stabilization 24 Vd.c./8
Vd.c. for knife upstroke control, various capacitors as well as light emitting diodes for voltage control.

4
V8
6
V9 8
V10
V11
V12
25V
0V KAP
24V MHS
0V MHS
030358
8V MHS
45V
0V
24V 26
0V
30
32

11 Accompanying documentation
18.02.2000 / ED_99gb3

The LED´s on power module board KAP indicate the following supply voltages:

LED Voltage Fuse Use Measurement at

V8 24V= F7 (4A) for keyboard KC PMX415.3 - PM X415.1

V9 45V= F10 (6A) for stabilitation board PS 95 PM X404.2 - PM X404.1
V10 24V= F3 (1,5A) for knife upstroke control MHS PM X416.8 - PM X416.9
V11 8V= F3 (1,5A) for knife upstroke control (SAP) PM X416.8 - PM X416.7
V12 25V= F4 (10 / 16A) for solenoids and solenoid valves PM X403.1 - PM X403.5
PM X416.1 - PM X416.5
30V~ F5 (2A) PM X402.1 - PM X402.7
15V~ F6 (2A) for Fixomat PM X402.1 - PM X402.5
230V~ F8 (5A=78-137 for Frequency Converter (FU), PM X413.4 - PM X413.5
6A=137-176) table light and optical cutting line PM X411.6 - MH X411.5

Power module 78 ES

The Powermodul for the machine 78ES is a transformator with three different secundary windings and
integrated rectifires for the voltage:
+ 8V = (Si1 1AT)
+ 25V.= (Si2 5AT)
+ 24V = (Si3 1AT)

The power supply unit G1 supplies + 5V =, + 12V = and G2 supplies +24V =

Si3 Si2 Si1

PE
230V~

+25V

+24V
0V~

+8V
0V

0V

0V

Accompanying documentation 12
 ED_99gb3 / 18.02.2000

Main drive 78 E

13 Accompanying documentation
18.02.2000 / ED_99gb3
Main drive 78 ES with neutral

Accompanying documentation 14
 ED_99gb3 / 18.02.2000

Main drive 78 ES without neutral

15 Accompanying documentation
18.02.2000 / ED_99gb3
Main drive 78 ED without neutral

Accompanying documentation 16
 ED_99gb3 / 18.02.2000

Main drive 78 ED without neutral USA / CSA

17 Accompanying documentation
18.02.2000 / ED_99gb3
Main drive 92

Accompanying documentation 18
 ED_99gb3 / 18.02.2000

Main drive 92 beginning with 6911001

19 Accompanying documentation
18.02.2000 / ED_99gb3
Main drive 92 USA/CSA beginning with 6911001

Accompanying documentation 20
 ED_99gb3 / 18.02.2000

Main drive 115 with Kimodul

21 Accompanying documentation
18.02.2000 / ED_99gb3
Main drive 115 - 176 with star-delta-switch

Accompanying documentation 22
 Main drive 115 - 176 with star-delta-switch without neutral
23

beginning from:

ED_99gb3
115 S/E/ED 6832201
Accompanying documentation

137 S/E/ED 6841601

155 S/E/ED 6921001

/ 18.02.2000
176 S/E/ED 69A1001
Accompanying documentation Main drive 115 - 176 with star-delta-switch without neutral USA / CSA

18.02.2000 / ED_99gb3
24

beginning from:
115 S/E/ED 6832201
137 S/E/ED 6841601
155 S/E/ED 6921001
176 S/E/ED 69A1001
 ED_99gb3 / 18.02.2000

Power modul 78 E, 78 ED and 92 - 176 with K304

25 Accompanying documentation
18.02.2000 / ED_99gb3
Power modul 78 E, 78 ED and 92 - 176 without K304

Accompanying documentation 26
 ED_99gb3 / 18.02.2000

Power modul 78 ES

27 Accompanying documentation
18.02.2000 / ED_99gb3

Power Supply 95 (PS95)

X1
The power supply board PS95 supplies three stabilized
+24 V (P2)
voltages: V1 F1 10A MTR
0 V (P2)
+24 Vd.c. Tolerance 23.7 to 24.3 Vd.c. F2 1,6 A MTR
+12 Vd.c. Tolerance 11.4 to 12.6 Vd.c.
+5 Vd.c. Tolerance 5.08 to 5.12 Vd.c.

The voltages cannot be adjusted! +12 V (P3)

V F3 10A MTR
0 V (P4)
While the control voltage is switched on or off the board
generates a reset signal to ensure a defined computer X2
function. The reset signal can be noticed by a brief flash
V3 RESET
of red LED V3.

Attention! This board is not compatible with the PS

board from the monitor machine! +5 V (P5)
V4
0 V (P6)

0V +45V

PM X404.2 1

ST-I X92.1 2

X1.15a,c-18a,c 20a,c-23a,c

RES +5V +12V +24V 0V

F1 F2 F3
10 A MTR 1,6 A MTR 10 A MTR
V3
V4 V2 V1
X2.7a,c X1.9a,c 1a,c-5a,c 7a,c-8a,c 10a,c-13a,c 25a,c-32a,c

CP CP CP I/O-BUS SAP
SAP SAP inputs for SAP
GC1 LS95 MHS (only 2 channel)
SK95 IMP
CP LS95
SK95
inputs for SK95

Accompanying documentation 28
 ED_99gb3 / 18.02.2000

Structure of Controls

ADA_D KC X503

DNT POLAR ED
*
7 8 9
4 5 6 x
1 2 3
C 0

ERW* I/O 5

X3
SHM 95 DNF 95 SFM 95 I/O PDR 95 SAP SK 95 CP XS1 GC1

* * * * * X4
*

SMP - BUS
* OPTION
* Printer

Compucut

Autocut

PC

Block diagram POLAR 92 - 176 E, ED (and 78 ED)

The block diagram illustrates the structural setup of KC X503

controls of machine types 92 - 176 E and ED. Series
POLAR 78E
78 - 137 S and 78 E correspond to the right illustrated 7 8 9

structure. 4

1
5

2
6

3
x

As specified in the block diagram, computer board CP

C 0

is the core piece of the control system. The remaining

plug-in boards are linked with the computer via two
independent bus systems (I/O and SMP, resp.). Data
is exchanged with the keyboard computer via serial I/O 5
interface X3 at the front side of the CP board. The
second serial interface X4 of CP is deliberately X3

configurable and allows the connection of any of the SAP SK 95 CP

peripheral equipments indicated. Should any other
X4
serial connections or additional RAM storages be
required, use board XS 1 (option).

Program data and information is indicated on three

different types of display. The machines of lines „S, * Printer

78 E and 78 ES“ are fitted with an LCD display (240 x Compucut

128), types E and ED can be equipped with a plasma PC

panel or a TFT colour display. These two displays have
a resolution of 640 x 480 pixels.

Block diagram POLAR 78 E, 78 ES

29 Accompanying documentation
18.02.2000 / ED_99gb3

Control unit with extention 1 for Polar 78 - 176 S, E and ED

plug in board side
Extention 1 Control unit

ERW 1 IO5
X23 X21 X19 X17 X15 X13 X11 X9 X7 X5 X1

XB XA XA

SHM DNF SFM I/O PDR SAP SK CP XS1 GC1 PS

X24 X22 X20 X18 X16 X14 X12 X10 X8 X6 ST-I

SMP - Bus

SHM DNF SFM I/O PDR SAP SK CP XS1 GC1

plug side
SAP PDR 826 I/O 5 ERW 96
F12 PDR 825 ERW 1 ERW 2
25 24 23 SAP 14
X 91 PM94 1 1 1 1 1 1 1 1
1
1 1
IMP
MHS

X 56
X 53
X 92
1 0V/25 DNF 307
SAP 98 I/O 4 SHM 202
X 93 PS95 I/O 3 1
1
1
SAP 105 1 1 1
1 1
1 SAP 99 1
1
SHM200
SK 5 SFM 54
1 SFM55
SK 65 SFM62 DNF51 1
I/O 2 1
63 +25V+24V +12V +5V 0V(MHS) 0V

1 1
1
SK 4 PDR 707 SHM201
SK 7 SK 66 SAP 97
1 1
1 1 DNF311
SK 11 SFM57
1
1
SK 9
1 SAP 107 SAP 26 I/O 1 DNF310 SHM203 1
SK 6 SK 12 1 1 1 1 1

1 1
SHM60
SFM 1
58 59
+ SK 52 SAP 106 1
1 SK 15 1
DNF308 SHM204
1
+
SAP 13 PDR 702 1 1
64

1 1
0V
0V 1

Accompanying documentation 30
 ED_99gb3 / 18.02.2000

Control unit Polar 78 ES

The control unit CU 78ES has the plug in spaces for CP, SK95 and SAP.
plug in board side

SAP SK CP

X5 X3 X1

X6 X4 X2

plug side
SAP 25

PM94
SAP 24

SK 5
SAP 23

SK 4 SK 15 SAP 98 SAP 105 SAP 13

62
UTH
UTH SAP 14
LST1 SAP 27
LST2 SK 52
SK 11 SK 65
F1
SK 9

63 SAP 106 SK 7
SK 6
SAP 107 SAP 97
SK 66
0V

31 Accompanying documentation
18.02.2000 / ED_99gb3

Central Processor CP

Computer board CP is fitted with a microprocessor S1 V1

type 186 which determines the complete machine RAM
cycle by means of two independent bus systems S1=RESET
as well as two serial interfaces. V4 FLASH-PROM V1=Computer activ
The software is stored in EPROMs or Flash- V4=Ref.-Point
EPROMs. The use of Flash-EPROMs offers the X1
advantage to install new software programs very X3=Keyboard KC
RAM X4=Printer, Compucut,
easily by using the Download Card (Download CP X3 Autocut
and/or KC).
FLASH-PROM
+
Board CP is linked with the boards on the left-hand
side (SK 95; SAP; PDR 95; I/O; SFM 95; DNF 95;
SHM 95) by the I/O bus. X4 ASIC
Linkage with the right-hand side (XS 1 and GC 1) 80C186 -
is established by the SMP bus (µP bus).

The board accommodates also RAM components

Jumper 1
buffered by a 3.6 Vd.c. lithium battery which contain open = Flash-prom X2
cutting program memories „A“ and „B“ as well as closed = Eprom
the variable machine data. OFF 12345678 ON OFF

SW2
OFF 12345678 ON OFF
SW3 CP 2
The front side of the board comprises:
S1 V1 S1=RESET
1. A reset key with integrated LED V1 „LED -
ON = computer active“ RAM V1=Computer activ
V4=Ref.-Point
2. LED V4 which indicates recognition of a V11-V14=Down-load
FLASH-PROM
reference point for backgauge positioning by X3=Keyboard KC X1
briefly lighting up X4=Printer, Compucut,
RAM Autocut
X3
3. Plug X 3 for serial interface of keyboard
controller (KC) on the keyboard FLASH-PROM
+
4. Plug X 4 is the second serial interface and can
be configurated via DIP switch SW 2.
X4
5. The Dip - Switch SW 2 serves for the adjustment -
to the machine versions as well as the display
version (see table). ASIC
80C186

6. The Dip - Switch SW 3 serves for the selction

of the default language, measurement unit and V4
X2
beginning with V4.0 the preselection of the
OFF 12345678 ON OFF
options autotrim and down-holder in front of the V14
V13 SW2
knife (see table). V12
OFF 12345678 ON OFF
V11
SW3 CP 4

Accompanying documentation 32
 ED_99gb3 / 18.02.2000

The program memory capacity: 99 programs per memory. Memory utilization is indicated in %.

The following information is part of the variable machine data:

Backgauge position, brake afterrun, creepage distance, table end, knife position, knife afterrun, selected
language, selected measuring unit, selected program as well as cut, cut counter etc.

The counting signals from backgauge positioning as well as the knife position are evaluated by a special
component (Asic) accommodated on board CP.

Software-Version

CP KC Changings

CP2 - Datum KC2 - V1.0 February 1995 to April 1995

CP2 - V1.0 KC2 - V1.0 April 1995

CP2 - V1.3 KC2 - V1.3 Window-Technique

CP2 - V1.3c KC2 - V1.3 Light barrier Test changed

CP2 - V1.3d KC2 - V1.3 new Display

CP2 - V1.4.0 KC2 - V1.4 new languages, new functions, new GC1 necessary

CP2 - V1.4.2 KC2 - V1.4 changed counting function of MHS-signals

CP2 - V1.4.3 KC2 - V1.4 custom made programm-versions

CP2 - V1.4.4 KC2 - V1.4 custom made programm-versions

CP2 - V1.4.5-13 KC2 - V1.4 changed handling of error message 608

CP2 - V2.1. Bed66 - V2.1 for 66E only

CP4 - V3.0 KC4 - V3.0 78 ED and 92 E/ED to 176 E/ED

Bed66 - V3.0 for 66E only
Bed78 - V3.0 for 78 ES only

CP4 - V3.0-13 changed handling of error message 608

KC4 - V3.0 78 ED and 92 E/ED to 176 E/ED
Bed66 - V3.0 for 66E only
Bed78 - V3.0 for 78 ES only

CP5 - V4.0 KC5 - V4.0 78 ED and 92 E/ED to 176 E/ED

Bed66 - V4.0 for 66E only
Bed78 - V4.0 for 78 ES only

33 Accompanying documentation
18.02.2000 / ED_99gb3

DIP - Switch SW2 and SW3 at CP

Preset of SW 2: Preset of SW 3:
- Machine type - Language selection
- Display version - Option down-holder in front of knife
- Service program - Option Autotrim installed
- optimized cut - Measuring unit
- presetting of plug X4
- Selection of knife change version

SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW SW
Type/Function 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 Type/Function 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8
66 ON ON ON Language Nr. 1 OFF OFF OFF OFF
S 78-137 Language Nr. 2 ON OFF OFF OFF
LCD-Display OFF OFF OFF
Language Nr. 3 OFF ON OFF OFF
78 E, ES, ED
LCD / TFT ON OFF OFF Language Nr. 4 ON ON OFF OFF
E 92-176 Language Nr. 5 OFF OFF ON OFF
mono Display
without Alphakeys OFF ON OFF Language Nr. 6 ON OFF ON OFF
E 92-176 Language Nr. 7 OFF ON ON OFF
color Display
without Alphakeys ON ON OFF Language Nr. 8 ON ON ON OFF
ED 92-176 Language Nr. 9 OFF OFF OFF ON
mono Display
with Alphakeys OFF OFF ON down-holder in OFF
front of knife ON
ED 92-176
color Display autotrim OFF
with Alphakeys ON OFF ON installed ON
Service- ON Measuring unit
Information OFF cm OFF OFF
Cutting ON Measuring unit
optimization OFF mm ON OFF
Interface Measuring unit
Printer OFF OFF inch OFF ON
Interface Measuring unit
Compucut ON OFF Sun ON ON
Interface
Autocut OFF ON

Knife change
"con-rod" ON

Knife change
"eccentric adjustm." OFF

Accompanying documentation 34
 ED_99gb3 / 18.02.2000

Available text versions for software version V1.x.x (CP2)

Text1 Text2 Text3 Text4 Text5 Text6

D German D German D German D German D German D German

GB English GB English GB English GB English GB English GB English
F French F French F French F French F French F French
E Spanish E Spanish E Spanish E Spanish E Spanish E Spanish
I Italian I Italian H Hungarian IL Hebrew A Arabic J Japanese
DK Danish P Portuguese PL Polish A Arabic T Tagalog ROC Korean
SF Finnish TR Turkish CZ Chzech PTM Bahasa T Thai
S Swedish GR Greek PI Bahasa CHI Chinese
N Norwegian NL Dutch RC Chinese

The textversions that have been marked are NOT available for Modell 78.

Available text versions for software version V1.4.x.x (CP2)

Text1 Text2 Text3 Text4 Text5 Text6 Text7 Text8

D German D German D German D German D German D German D German D German

GB English GB English GB English GB English GB English GB English GB English GB English
F French F French F French F French F French F French F French NL Dutch
S Spanish S Spanish S Spanish S Spanish S Spanish S Spanish S Spanish CHI Chinese
I Italian I Italian H Hungarian IL Hebrew A Arabic J Japanese CHI Chinese RP Tagalog
DK Danish NL Dutch PL Polish A Arabic RP Tagalog ROK Korean T Thai PTM Bahasa
SF Finnish P Portuguese CZ Chzech RP Tagalog IR Farsi RC Chinese RI Bahasa
S Swedish TR Turkish RUS Russian RC Chinese
N Norwegian GR Greek RO Romanian

The textversions that have been marked are NOT available for Modell 78.

Available text versions for software version V3.x.x (CP4)

Text1 Text2 Text3 Text4 Text5 Text6 Text7 Text8

D German D German D German D German D German D German D German D German

GB English GB English GB English GB English GB English GB English GB English GB English
F French F French F French F French F French F French F French NL Dutch
S Spanish S Spanish S Spanish S Spanish S Spanish S Spanish S Spanish CHI Chinese
I Italian I Italian H Hungarian IL Hebrew A Arabic J Japanese CHI Chinese RP Tagalog
DK Danish NL Dutch PL Polish A Arabic RP Tagalog ROK Korean T Thai PTM Bahasa
SF Finnish P Portuguese CZ Chzech RP Tagalog IR Farsi RC Chinese RI Bahasa
S Swedish TR Turkish RUS Russian RC Chinese
N Norwegian GR Greek RO Romanian

The text versions that have been marked are ONLY available for color-displays.

Available text versions for software version V4.x.x (CP5)

Text1 Text2 Text3 Text4 Text5 Text6 Text7 Text8 Text9

D German D German D German D German D German D German D German D German D German

GB English GB English GB English GB English GB English GB English GB English GB English GB English
F French F French F French F French F French F French F French NL Dutch H Hungarian
S Spanish S Spanish S Spanish S Spanish S Spanish S Spanish S Spanish CHI Chinese CZ Chzech
I Italian I Italian H Hungarian IL Hebrew A Arabic J Japanese CHI Chinese RP Tagalog RUS Russian
DK Danish NL Dutch PL Polish A Arabic RP Tagalog ROK Korean T Thai PTM Bahasa RO Romanian
SF Finnish P Portuguese CZ Chzech RP Tagalog IR Farsi RC Chinese RI Bahasa YU Serb
S Swedish TR Turkish RUS Russian RC Chinese CRO Croatian
N Norwegian GR Greek RO Romanian SLO Slowenian

The text versions that have been marked are ONLY available for color-displays.

35 Accompanying documentation
18.02.2000 / ED_99gb3

Backgauge Drive Positioning (SAP)

The SAP board is linked with computer CP via the I/O bus. The information input is signalled to the
computer via this bus. The same bus is used for sending the output commands of the computer which
are then transferred as output signals by the SAP board to the machine. The board also accommodates
the decoding circuitry of the knife upstroke control (MHS 95) at the worm wheel shaft.
The SAP board includes the following functions which are indicated by LED´s:
yellow LED´s indicate Inputs - red LED´s indicate Outputs

LED Colour Meaning Basic condition SAP

V29 yellow UT1(lower dead centre) of MHS 95 off MP1

V28 „ OT1(upper dead centre) of MHS 95 off MP2
V27 „ UT (lower dead centre) of MHS 95 off
V26 „ OT (upper dead centre) of MHS 95 on P1/0V
(Offset)
V6 red Backgauge motor brake Y17 on (free) off
V5 yellow End posit. at front, with false clamp off V29
plate and Fixomat V28
V4 red not used off V27
V3 „ Control signal backgauge return for off V26
V6
frequency converter V5
V2 „ Control signal backgauge advance off V4
for frequency converter V3
V1 „ Enabling signal for FU* off V2
V25 yellow 0° signal from MHS 95 on/off V1
V24 „ 90° signal from MHS on/off V25
V24
V23 „ Limit switch front (S9) on
V23
V22 „ Fixomat active off V22
V21 „ Limit switch rear (S 13) on V21
V20 „ Handwheel precision adjustment (S 18) off V20
V19 „ „ „ " (S 14) off V19
V18 „ „ „ " (S 10) off V18
V17
V17 „ Pedal switch (S390) off
V16
V16 „ False clamp detection 3 (S 218b) off V15
V15 „ False clamp detection 2 (S 218) off V14
V14 „ False clamp detection 1 (S 6) off V13
V13 „ Limit switch front slowly (S 7) on V12
V12 „ Limit switch rear slowly (S 13a) on

The following input and output signals are not indicated by LEDs:
(indicated on the display in the „Service“ section)
Input from switch B 340 for knife wrench (cover plate in front of knife lift)
Inputs from pulse generator = 0° signal, 90° signal and reference point
Input from „mechanical“ reference point B 341 (proximity switch below table)
Input error signal from FU
Input error signal from table motor (thermal protection contact)
Input „upstroke terminated“ from control unit of main motor (SDS or KIMODUL)
Input „Backgauge advance movement blocked by external device“ (Transomat 3BL, gripper
systems)
Output Control signal to FU (0 to +10 Vd.c.)
Output UTH from knife upstroke control to SK 95
Output UTH neg. from knife upstroke control to SK 95
Output Counting pulses from knife upstroke control to CP (knife position)

Accompanying documentation 36
 ED_99gb3 / 18.02.2000

Calibration Instructions for SAP Board during Operation

with Frequency Converter
(Valid for all machines with frequency converter)

1. Connect a digital multimeter to measuring points MP1 (+) and MP2 (-).
2. Activate one time the backgage movement
3. Use potentiometer P1 to set a voltage of 0.0 V (+/-0.1) (offset) with the control system
switched on.
4. Perform a reference run.

Activation of frequency converter by card SAP

The frequency converter is activated by card SAP and consists of an analogue signal between 0V and
+10Vd.c. corresponding to the backgauge speed preset by the computer. In standard operation the analogue
signal is identical for both directions (advance and return movement of backgauge).

backgauge movement manual slow manual fast positionanalogue

signal SAP> FU approx. +3.3 V approx. +6.6 V approx. +10V
The control of the direction of rotation is also performed by card SAP and indicated by LEDs V3 (return
movement) and V2 (advance movement), resp.

Position Measurement

On machines of lines S, E, ED ... position measurement is performed by means of a hollow-shaft pulse

generator which is fixed directly onto the end of the spindle. This arrangement offers the advantage that
the spindle rotation is directly transferred into counting pulses, i.e. there are no further offsets which might
constitute possible sources of error. The pulse generator housing is fastened onto the machine table by
means of a spring. The shielded connecting cable is directly linked with the base plate (plug interface ST-
I) via plug X23.
The pulse generator is fed with 24 Vd.c. and supplies the SAP board with 0° and 90°-signals during
spindle rotation and with one reference pulse per rotation. Since the pulse transducer supplies one reference
signal during each rotation, this signal together with the signal from proximity switch B341 „mechanical
reference point“ is conditioned to an AND-operation on board SAP. All signals are converted in the SAP
board and supplied to computer card CP.

Illustration of Backgauge Movement (Ramp)

backgauge speed

45 / 60 Hz
20 / 27/sec.

creep speed 2Hz

2 Hz
ap. 0,9 cm/sec.
backgauge position

slow down travel brake afterrun

37 Accompanying documentation
18.02.2000 / ED_99gb3

Reference point
In the new machine generation the reference point is composed of two signals. During every rotation the
pulse generator generates a signal. To specify only one of these signals a proximity switch B341 is located
beneath the table. The reference point is recognized by card CP when both signals are given simultaneously.
The result is displayed in the "service" menu under "machine data":
Example: 53.635 cm / 54.256 cm / 54.671 cm
B341 ON IMP B341OFF

The left-hand number (53.635 cm ) describes the connection of proximity switch B341 by the switching
flag at the sledge. The number in the centre, (e.g. 54.256 cm ) indicates the signal given by the pulse
generator. The right-hand number (e.g. 54.671 cm) specifies the disconnection of proximity switch B341
by the switching flag at the sledge. The second (medium) number should be in the centre between the
connection and disconnection points of B341.To make the setting, position the number indicated in the
service section (e.g. 54.256 cm) for the signal of the pulse generator. Center the switching flag directly
over the proximity switch.

Reference run

To determine the current position the central

processor must be given a reference. This S13
is generated by linking the active proximity
switch B341 and the reference signal given
by the pulse generator. The reference point
can be determined by calling the function
"reference run" automatically or from the
menue "preset of functions". In this cause, B341
the backgauge is automatically moved
forward and backward searching the travel
distance to find the reference point. Besides Stop
the reference point other information is also Start
recorded for the operation of the machine,
such as maximum backgauge position,
slow-down travel, brake afterrun and max.
velocity.
If no reference point has been found you
can work in secondary operation.

Backgauge Drive Unit with Frequency Converter

On all machines with standard equipment backgauge motor control is performed by a frequency converter.
The motor in question is a standard three-phase motor with a brake flanged onto it. Power supply of 230
Va.c. for the frequency converter is picked off the primary side of the control transformer protected by fuse
F8 on power module board DC (X3). The frequency converter is activated from board SAP by an analogue
signal between 0 V and 10 Vd.c. corresponding to the backgauge speed preset by the computer. Direction
of rotation is also controlled by board SAP and indicated by light emitting diodes V3 (reverse movement)
and V2 (advance movement).
The frequency converter drives the backgauge motor by means of a three-phase current within a frequency
range of 2 to approx. 65 Hz, depending upon the machine size.
The backgauge motor brake (24 Vd.c.) is also activated from board SAP and indicated by LED V6. (The
brake is the same type as on EMC and monitor machines.

Accompanying documentation 38
 ED_99gb3 / 18.02.2000

Frequency Converter Lenze 8200

Three different frequency converters are employed with the cutting

V1 V2
machines. Backgauge drive units of machines 78 are fitted with an Lenze FU
Display
0.375-KW converter, 92 to 115 are fitted with an 0.75-kW converter,
whereas machines 137 to 176 are equipped with 1.5-kW units. The 1
SH PRG
STP

devices are precalibrated at the producer‘s, precision adjustment is 1

RUN

made during machine final acceptance at POLAR Mohr. 62 20

7 28
In the case that a device must be replaced at the customer‘s, cali- 8 E1
9 E2
bration must be checked and performed again, if necessary. This K11
K12
E3
E4
K14 39
requires the use of a detachable programming unit (Id. no. 229709).
This device with the respective operating instructions can be
purchased from Lenze company and must be available as an
auxiliary tool at any of our agencies. W
The programming unit can be connected to, or disconnected from, V
U
-UG
the frequency converter with the power on or off. +UG
N
L1
PE

Operating and adjustment instructions for LENZE converter 8200

The control states are indicated by the following LEDs on the front:

LED green red Meaning

flashing off stand by

active off converter activ
off flashing (1s) Error
off flashing (0.4s) check power supply
off off programming mode

For all settings of the converter use the key pad (key board 8201 BB)

The button functions are:

STP Stop frequency converter

PRG switch over to programming mode
SH show parameter
Attention! use only parameter 1 (PAR1)
PRG+SH storing off adjusted parameter
/ scrolling in porgramming mode and selecting of parameter
RUN switch unit to stand by

39 Accompanying documentation
18.02.2000 / ED_99gb3

For pre-adjustment of the frequency converter unit use:

jumper for input level (1 and 2 has to be conected for input from SAP-board 0V up to +10V)
setting of defaults from manufacter LENZE
setting of parameters for POLAR equipment

Presetting of Jumper
Converter disable
In case a frequency converter must be replaced at the customer‘s, the LED green = flashing
jumper position must be corrected. Jumper position 1-2 for signal 0 to LED red = off
+10 Vd.c. from board SAP to FU is required. converter in stand by
switch to code level
Procedure for bringing the converter PRG
back to to basic settings (default)

The frequency converters 8200 supplied through POLAR have been Code-level
factory adjusted. The presetting serves to provide a faster adaptation of
select Code
the frequency converter to the needs of POLAR cutters. The factory /
adjustment can be taken over into the first parameter set (PAR1) in the
following way:
switch to Parameter level
Plug in key pad SH 1 time only!
1. Press key „PRG“ of programming unit (switches from operating
level to code level).
2. Use key „ “ or „ “ to select step C002. Parameter level
3. Key „SH“ switches over to the display of the current value use Par 1 only!
(parameter level). change Parameter
4. Use any of keys „ “ or „ “ to select value 1. /
5. Press keys „SH“ and „PRG“ simultaneously.
Changeover is acknowledged by „SET 1“.
6. Press „RUN“ key. program new Parameter
PRG + SH

Attention! Continue with the following instruction for the setting

of parameters for POLAR Cutters, by adjusting of step C008, C010, leave Code level
C011, C012, C013, C015 and C016. PRG

Procedure for setting Converter in stand by

the parameter for POLAR cutters

The current set of parameters (PAR1) can be checked and modified

manually.
1. Clip programming unit „8201BB“ onto frequency converter
2. Press key „STP“.
3. Use key „PRG“ to switch over to code level.
4. Use key „ “ or „ “ to preselect the desired parameter set.
5. Press key „SH“ (Changeover to parameter level)
6. Modify the current value (parameter) by means of key „ “ or „ “
7. The new parameter is stored by pressing keys „SH“ and „PRG“, simultaneously.
Indication „STO“ acknowledges the procedure.
8. Return to operating level by pressing key „PRG“.

Accompanying documentation 40
 ED_99gb3 / 18.02.2000

Depending upon field application and Polar cutter type, the parameter values have to be set at the frequency
converter according to the following table.

Code Meaning 78 92 115-137 137 - 176

frequency converter 8201 8202 8202 8203

KW 0,375 0,75 0,75 1,5
C001 operating mode 0 0 0 0
C007 wiring configuration 0 0 0 0
C008 relais configuration 9 9 9 9
C010 min. frequency 2Hz 2Hz 2Hz 2Hz
C011 max. frequency 45Hz 45Hz 65 Hz 65 Hz
C012 accelration ramp 0.05 0.05 0.05 0.05
C013 decceleration ramp 0.05 0.05 0.05 0.05
C014 C/M 0 0 0 0
C015 U/F 50Hz 50Hz 50Hz 80Hz
C016 min. Voltage 8-15% 10-20% 10-20% 10-20%

motor wiring

Parameter C016 must be adapted to the machine. The higher the value in parameter C016 the higher is
the power consumption upon the start of the backgauge and during extremely slow backgauge movements.
An excessive power consumption may cause the backgauge movement to be cut off with an error message
being issued.

The parameter C016 affects the current output

during the backgauge start. If the output is to
high you may get a stop because of overcurrent
and following error messages. The setting is 15 Hz
o.k. if you do not have more than four up to five
max. 4-5 dots
dots in the display shown during scanning of
during scanning
the reference point. Wich is the most stressfull STP
the reference point
situation for the backgauge motor. SH PRG
RUN

41 Accompanying documentation
18.02.2000 / ED_99gb3

Using key pad for showing output level of the frequency converter

1. Plug keypad „8201BB“ into the frequency converter.

2. Prepare a programm with to steps

PE 70.000

PE 20.000

and activate in automatic mode the backgauge movement.

3. Push "PRG" of the keypad "8201BB".
4. Select for example code C050 by using the scroll buttons.
5. Key "SH" Key „SH“ switches over to the display of the current value.
6. After cheching the function push twice the key „PRG“.

During activ backgage movement (automatic) the display of the frequency converter show:

Code Meaning 78 92 115-137 137-176

C050 actual frequency in Hz 2-45 2-45 2-60 2-60

C052 Power supply for Back gauge motor 40-220 40-220 40-220 40-220
C054 act. output in A <2,6 <4 <4 <7
C061 internal temperature <90°C <90°C <90°C <90°C

the max. output can be 150% for one second

Error messages issued by the frequency converter

(displayed on programming unit 8201BB)

C161 Actual error

C162 Last error
C163 One before last error
C164 Two before last error

LU Supply voltage too low: check supply voltage; correct transformer tapping, if necessary.
OV Supply voltage too high: check supply voltage; correct transformer tapping, if necessary.
OC1 Short circuit at motor output: check motor cable for short circuit, check back gauge motor
OC2 Earth fault at motor output: check motor cable for earth fault, check back gauge motor
OC3 to OC6 Overloading of devices: adjustment of parameter sets, check motor and cabling
OH Excessive heat sink temperature: check ambient temperature, clean heat sink
PR to PR2 Error in data transfer: transfer data again or load factory setting before controller is enabled,
use other programming unit

Accompanying documentation 42
 ED_99gb3 / 18.02.2000

Block Diagram of Backgauge Drive by Frequency Converter

(sample - backgauge advance manually)

+24V +24V +24V +24V +24V +24V

B341 S10 S9 S7 S13a S13

Ref.
90° V18 V23 V13 V12 V21
o°
SAP I/O - Bus CP
V6
V1 V2/3

+25V

8 28 E4 39 7

FU 08 = 0 .... 10 V=
FU FU 28 = enable (V1)
= advance (V2)
FUE4
= reverse (V3)
L1 N U V W
FU 39 = 0V / ground

230V~

M WSK
Y17 3~

0V
0V Backgauge motor 78 (0,375 kw FU)
92-137 (0,75 kw FU)
0 degree
IPG 1 Terminal box
90 degree
reference point
Backgauge motor 137-176 (1,5 kw FU)

Terminal box

43 Accompanying documentation
18.02.2000 / ED_99gb3

Backgauge start after cut and Function of S390

EL, CE, EMCI, EMCII V1.0 and

S, E, ES, ED if clamp optimization is used in level 1

S22a + S22b (MHS) S29 or B29 active backgauge start

knife in UDC clamp on top

EMCII V2.0 ....., S, SD, SD-P, EM, EM-Monitor, EMC-Monitor

foot pedal during B29 active

cut active clamp on top
S22a + S22b backgauge
S390
knife in UDC start
foot pedal during time delay
cut not active

S, E, ES, ED if clamp optimization is used in level 2 ... 9

foot pedal during

S390
cut active
MHS backgauge
S390 time delay
knife in UDC start
foot pedal during cut
not active

ED if cut optimization is activ

foot pedal during

Sensor S390
cut active
in clamp reports Backgauge
knife above S390 time delay
start
clamp front edge foot pedal during cut
not active

Accompanying documentation 44
 Diagram SAP and backgauge positioning 78 - 176 S/E/ED
45

ED_99gb3
Accompanying documentation

/ 18.02.2000
18.02.2000 / ED_99gb3

Cutting Circuit (SK 95)

Trouble free operation of the cutting cycle is ensured by the cutting circuit board. The hardware logic of
this board together with the software of central processor CP generates the energizing of hydraulic valves
and safety lever (SB) during pressing and cutting.
Board SK 95 is not compatible with board SK used in previous monitor machines!

The control states are indicated by the following LEDs on the front side of board SK 95:
SK

LED Colour Meaning Basic condition V83

V84
V83 red Safety lever (YSB) off V85
V84 „ Cycle f. cutting circ. transformer - press.-Y27, Y27a off V86
V85 „ Light barrier test terminated positively off V87
V86 „ Cut buttons actuated correctly (within 0.5 sec.) off V88
V87 „ Control signal for safety lever (nomin. condit.) off V89
V88 „ Logic error in cutting circuit (reset) off
V89 „ Cycle f. cutting circ. transf. -cutting- (Y33, Y33a) off
V71 yellow Safety lever in blocking position (B SB e) on
V72 „ Safety lever unblocked (B SB a) off V71
V72
V73 „ NC contact right-hand cut button on
V73
V74 „ NC contact left-hand cut button on V74
V75 „ NO contact right-hand cut button off V75
V76 „ NO contact left-hand cut button off V76
V77 „ Knife upstroke (UTH = lower dead centre upstroke) from SAPoff V77
V78 „ Knife descending (UTH neg.) from SAP on V78
V79 „ Clamp at upper position (B29) on V79
V80 „ spare off V80
V81 „ Pedal switch (S309) off V81
V82
V82 „ „Table air“ key „ON“ off
+25V
At the measuring socket at the lower edge of the SK 95 board the non stabilized voltage
of +25 Vd.c. (approx. +25V - +28V d.c.) can be measured.

Knife Upstroke Control (MHS 95)

Knife upstroke control unit constitutes a closed unit which is fastened onto the crankshaft journal of the
gearbox by means of a screw. The unit is fastened by means of a fixed centering bolt at the gearbox
housing to secure it against twisting.
Mechanical adjustment is not possible!
The knife upstroke control unit has an arrangement of infrared transmitting and receiving diodes which
scan a punched disk. The signals are led through an integrated cable via plug no. 25 to the plug interface
board and conditioned in plug-in board SAP for SK 95 as well as the CP computer.
The complete MHS 95 unit with connecting cable constitute one single spare part.

Accompanying documentation 46
 ED_99gb3 / 18.02.2000

The knife upstroke control (MHS 95) supplies the SAP board with the following signals:
The graphic shows the light emitting diodes‘ indication on boards SAP and SK95 during the cutting cycle.

MHS 95

SAP CP

Counting-
pulses
SK95
V29
V28 UTH V77
V27
V26 UTH V78

+24V +24V +24V +24V +8V +5V +12V +24V

PS95 KAP > MHS PS95

UDC/0° BDC/180° UDC/360°

SAP V29
UT1

SAP V28
OT1

SAP V27
UT

SAP V26
OT

SAP V25

SAP V24

SK95 V77
UTH

SK95 V78
UTH

47 Accompanying documentation
18.02.2000 / ED_99gb3

Cutting circuit

function reaction LED SK-board

Reset of SK board SK-Reset OFF V88 OFF or I/O in service

Check of inputs BSB.E V71 ON
BSB.A V72 OFF
S28a - S28b V73 and V74 ON
V75 and V76 OFF
Y315
V77 OFF
MHS (SAP) V78 ON

activate cut buttons S28a + S28b V73 and V74 OFF

check disabling of clamp by CP2 V75 and V76 ON
simultaneously using of cut button
480 msec. V86 ON
LS-Test LS change to low
LST change to high
LS-NOT change to high
LS-Test o.k. LS change to high
LST change to low
LS-NOT change to low V85 ON

activate Clamp pressure Y315 activ V84 ON

Y27 activ and Y27a activ
internal delay plus operator setting
recording to different software-version
B29 deactivated V79 OFF
check disabling of cut by CP
activate SB including time control YSB activ V87 ON
BSB.E change to low V71 OFF
BSB.A change to high V72 ON

activate clutch Y33 activ and Y33a activ V89 ON

feedback of counting pulses from
MHS
from V1.4: max. 0,5 sec.
checking of counting pulses
time out control during downstroke
TDC > BDC: max. 2sec. UTH change to high V77 ON
UTH not change to low V78 OFF
YSB OFF V87 OFF
Y315 OFF
Y27 + Y27a OFF V84 OFF
time out control during upstroke
BDC > TDC: max. 1,4 Sec. UTH change to low V77 OFF
UTH not chnge to high V78 ON

deactivate clutch Y33 + Y33a OFF V89 OFF

check knife afterun
release clamp Y315 activ
Clamp at the top B29 activ V79 ON
deactivat Y315 after time delay Y315 OFF

Accompanying documentation 48
 ED_99gb3 / 18.02.2000

Cutting operation

The illustration below shows the function (LED indication on board SK95) of hydraulic valves and safety
lever (SB) during the cutting cycle.

0°/360°

180°

start of cutting cycle

0° 180° 360°/0° B29/V79

Y SB
LED V83

Y 33+33a
LED V89

Y 315

Y27+27a
LED V84

49 Accompanying documentation
18.02.2000 / ED_99gb3

Light Barrier (LS 95)

In accordance with the „Berufsgenossenschaft Druck und Papier“ (German employer`s liability insurance
association) as well as the mechanical engineering regulations of the European Union we developed an
infrared light barrier with nineteen (since Nov. 96 twenty) channels which is employed as of machine types
S, E, ED, .. This light barrier consisting of a transmitting and a receiving unit has a new design and is
accommodated in a new type of housing. The two p.c. boards form one spare part, each, which means
that no replacement of individual transmitters or receivers is possible.
When installing the light barriers care must be taken that the two light barrier (LS) housings are aligned
and fastened onto the adapter plates of the front side at right angles to the front table. Calibration can be
made by means of the indicator panel located in the left-hand LS housing.

The light barrier is supplied with 24 Vd.c. on the transmitter side and 24 Vd.c. as well as 12 Vd.c. on the
receiver side. The LS 95 is an independent unit. The two exclusive OR outputs „LS high“ and „LS low“ are
linked with board SK 95 via plugs 600.8 and 600.9. When the cut is released the cutting cycle generates
test signal LST1 and board SAP generates one more test signal, LST2 as soon as the knife has reached
the lower dead centre or the cut or pressing process has been interrupted.

Indicator Panel of Light Barrier

Meaning of light emitting diodes of the display panel

D1 D2 D3 D4 D5 D6 Meaning

ON ON ON ON OFF OFF Protect. area „unobstructed“, light reception excellent

OFF ON ON ON OFF OFF Protect. area „unobstructed“, light reception good

OFF OFF ON ON OFF OFF Protect. area „unobstructed“, light reception just sufficient

ON ON OFF OFF ON ON Protect. area obstructed or test being performed

OFF OFF OFF OFF ON ON Protect. area was never „unobstructed“ since „Voltage ON“

flashing OFF OFF ON ON Error

Accompanying documentation 50
 Block diagram Cutting circuit

B.SBA
B340 LS-transmitter LS-receiver B.SBE B29
MHS S28b S28a
95 +24V +24V

S390 S309
LS - Test2
I/O - Bus

V26 V27 V28 V29 V74 V76 V73 V75 V71 V72 V79 V81
OT UT OT1 UT1
V17
LS - Test1
SAP SK95 CP
51

V24 V25
90° 0° UTH V77 PR MS V83
UTH V78 V84 V89

SKÜ SKÜ
~ ~

ED_99gb3
Accompanying documentation

7,5 Ohm
36 Ohm

36 Ohm

36 Ohm

36 Ohm

22 Ohm

/ 18.02.2000
Y27 + Y27a Y33 + Y33a Y315 Y.SB
Accompanying documentation Diagram SK95 and Cutting circuit 78 - 176 S, E, ES, ED

18.02.2000 / ED_99gb3
52
 ED_99gb3 / 18.02.2000

Hydraulic System 92 -176 S, E, ED

(Hydraulic System 91)

The hydraulic system 91 installed on all S, E ED 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)
2 ball type magnetic valves P1 (Y27 + Y27a)
1 working cylinder

3
1 control unit P2
2 ball type magnetic valves P2 (Y33 + Y33a) 2 1
1 additional flow governor P1 (only 92)

Arrangement

The entire system is located in the right frame pillar which serves also as Oil tank.
Since may 1996 the valves are supplied with new style plugs.

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 (= clam- P2 P1
ping) 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 91 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.

53 Accompanying documentation
18.02.2000 / ED_99gb3

Control units

Flow circuit P1 (= clamping) comprises devices which can be exchanged separately in case of possibly
arising malfunctions. Flow circuit P2 (= clutch) has only one control unit.

The control unit P1 comprises the following valves and slide valves:
1. Control unit P1
a) pressure relief valves for 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
2. conical valve (Y315) / M1
3. ball type magnetic valves (Y27 + Y27a) / M3

The control unit P2 comprises the following components:

1. Control unit P2
a) pressure relief valve for clutch pressure
b) manometer connection P2
2. ball type magnetic valves (Y33 + Y33a) / M2

Pipe fitting

The hydraulic pipes fitted within the frame pillar, are connected to the cylinder via the base-plate to whitch
the control units and valves are mounted.
The complete base-plate with the control units and valves, can be taken off by dismounting four screws.
Sealing between the cylinder, base-plate, control units (P1 and P2) and valves is achieved with "O" rings.

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 optio-

nal equipment (stacklifts and retractable sidegauges) 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
4. blind plates for not used functions

Accompanying documentation 54
 ED_99gb3 / 18.02.2000

P1 - Oil Flow Circuit

Working cylinder

reservoir
Y315

Pressure reduction valve

M Slide piston for

cutting line indicator

Pressure
regulation
valve flow governor

safety
pressure
valves
additional flow governor
92 only

+5bar

Y27 Y27a

2 channel hydraulic only

55 Accompanying documentation
18.02.2000 / ED_99gb3

Description of functions

On the hydraulic system 91 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 turnknob 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 put on, 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
connection of P1 to the tank.
Switch S309 is actuated via a se-
cond cam. Thereby the plug-in-
board “SK” (Cutting circuit)
energizes the conical valve Y315 Working cylinder
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 reservoir
the flow governor of control unit Y315
P1.
When the pedal is released, the Pressure reduction valve
control slide valve moves back to
its initial position restoring the Slide piston for
connection of P1 to the tank. Now M cutting line indicator
the spring draws the clamp
Pressure
upwards and the oil in the working regulation safety
cylinder is pressed back to the valve pressure
tank via conical valve Y315 and valves
the control slide valve. The
Cutting circuit SK95 keeps +5bar
conical valve Y315 energized until additional flow governor
flow
92 only
the clamp has returned to its governor
resting position and proximity
switch B29 is activated.

Y27 Y27a
2 channel hydraulic only

Accompanying documentation 56
 ED_99gb3 / 18.02.2000

Clamping without cut

The function “clamping without cut” is initiated by actuating the cut buttons which causes the magnetic
valves Y27, Y27a and Y315 to become energized. Magnetic valves Y27 + Y27a block 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 gained, the switching piston will divide P1 into a 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 turn-knob) and a low pressure circuit with
a maximum pressure of 40 bar. This pressure appears at the ball type magnetic valves Y27 + Y27a
which block the oil circulation to the tank. With cut buttons released ball type magnetic valves Y27 + Y27a
becomes deenergized opening the line for the oil of P1 to flow back into the tank. The conical valve Y315
remains energized until the clamp has returned to its upper position and B29 is activated.

Working cylinder

reservoir Y315

Pressure reduction valve

M
Slide piston for
Pressure
cutting line indicator
regulation
valve
safety
flow pressure +5bar
governor valves
additional flow governor
92 only

Y27 Y27a
2 channel hydraulic only

57 Accompanying documentation
18.02.2000 / ED_99gb3

Cut function

Upon actuation of the cut buttons the two valves Y27, Y27a and Y315 of circuit P1 become energized first
as described above. With time delay after the valves of P1, ball type magnetic valves Y33 + Y33a of P2
is energized. The delay time for Y33 + Y33a may be varied by the operator.
After magnetic valves Y33 + Y33a has been energized, the knife moves down. When the knife has
passed bottom dead centre the two valves Y27 + Y27a and Y315 become de-energized by the MHS and
the control circuit, which leaves the clamp in its lowered position, as the de-energized conical valve Y315
blocks the line from the cylinder to the tank.
Controlled by the MHS at the gear the knife moves upwards. After having returned to top dead centre, the
ball type magnetic valve Y33 + Y33a of circuit P2 becomes de-energized and the knife stops.
At the same time the conical valve Y315 becomes energized again and the clamp returns to its upper
resting position. At the end conical valve Y315 becomes de-energized when B29 is activated.

In case a down-stroke of the knife is interrupted, all three magnetic valve instantly become
deenergized. Knife and clamp will stop immediately.

M M
clutch cylinder clutch cylinder

2 Channel hydraulic 2 Channel hydraulic

only only
Y33a Y33a

Y33 Y33

pressure pressure
regulation valve regulation valve
for clutch for clutch
92 = 60 bar 92 = 60 bar
115 = 70 bar 115 = 70 bar
137 = 75 bar 137 = 75 bar
155 = 90 bar 155 = 90 bar
176 = 90 bar 176 = 90 bar

Accompanying documentation 58
 ED_99gb3 / 18.02.2000

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 SHM first energizes 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 for the respective cylinder into which then the oil is pressed.
At the same time cutting and clamping operations are blocked electrically and hydraulically.
If for an operation to be performed by the optional hydraulic system no pressure is required, only the
respective conical valve is energized. The switch-over valve Y330 remains de-energized.

Bleeding the hydraulic system

Caution!
The slightest amount of air in the hydraulic system may cause malfunctions.

bleeding of
clutch cylinder

bleeding of
working cylinder

manometer connection
clutch pressure

manometer connection
clamp pressure

59 Accompanying documentation
18.02.2000 / ED_99gb3
Reservoir label 2 channel hydraulics 92 -176

+5bar

Accompanying documentation 60
 Reservoir label 1 channel hydraulics 92 -176

61
+5bar
ED_99gb3

Accompanying documentation
/ 18.02.2000
18.02.2000 / ED_99gb3

Hydraulic System 78 S, E, ES, ED

The complete hydraulic system is located inside the right frame pillar. The pillar is also the hydraulic oil
tank. All individual components of the hydraulic system, except the pump, are mounted above the oil
level. The hydraulic cylinder is mounted upright within the frame pillar. The hydraulic pump transfers the
oil from P1 through the cylinder back to the tank with a circulation pressure of 1-2 bar as soon as the
machine has been turned on. Engaging the two cut button will activate the valves in the P1 circuit and the
clamping pressure is applied.
The cut will be controlled by a electro-magnetic clutch. The necessary clamping pressure can be set by a
turn knob.

Hydraulic cylinder bleeding

screw

The working cylinder has two working chambers with a piston with 2 diffe-
rent diameter of working surfaces. To achieve a fast down motion of the
clamp, the oil flow is directed first to the smaller piston chamber. The piston
will move out and by the creation of vacuum, additional oil from the tank is
pulled in the larger chamber. Within the center section of the cylinder is
located a pressure reduction valve, which at a pressure of 32 - 35 bar
(depanding on the type of machine), moves the spring tensioned change
over piston closing the oil intake from the tank. The pressure increases in
the small cylinder area, as the difference in pressure between the two
chambers exceeds 38 bar, the spring tensioned conical seal in the pressure
reduction valve opens and the selected clamp pressure will now take effect
in both cylinder areas.
The pressure will subside as soon as the cutting cycle is complete. The
relief valve at the center section ot the working cylinder opens up and the
oil from the large cylinder area can flow back into the reservoir via P1.
When the pressure diminishes to 34 bar, the change over piston opens
and the oil can now also flow back through the suction opening. The clamp
reverse spring pushes the working cylinder piston back to the initial starting
position. Cross boring in the center section of the working cylinder in con-
junction with a ball valve, make possible a smooth return and stop of the
clamp. During the inward movement of the piston within the last third of the
travel, more and more cross bores become closed
and with it the ball valve. The oil return from the
small cylinder area (6) is restricted and a soft
clamp return is accomplished.

Attention !

If a hydraulic cylinder is being exchanged, make sure that no airgap exist between
cylinder and cylinder support pillar. If necessary fill up with spacers.

Accompanying documentation 62
 ED_99gb3 / 18.02.2000

Hydraulic pump

Tooth wheel pumps are used on POLAR machines, which

are reliable and simple in design. The pump used on Model
76 has only one oil flow circuit P1. The pump is located below
the oil level and is being driven from the main motor by a V-
belt.
It is very important to have the pump never run dry, as
otherwise the pump will be damaged.
It is equally important that the correct direction of rotation is
observed.

Control unit

The complete control block is fixed at the cylinder by means of two screws and is aligned by two dowel
pins. Sealing is achieved using "O" rings.

The complete P1 control comprises:

Clamp pressure regulating valve

Conical valve Y315
Ball safety valve Y27 and Y27a
Manometer connector

Clamp pressure regulating valve

The clamp pressure regulating valve (adjustable relief

valve), is connected to the P1 oil flow line.
By turning the pressure knob (1), the stepless adjustment
is transmitted to the clamp pressure regulation via an
adjustable rod (2).

Attention !
The pressure can only be checked during the cutting
cycle.

Cut interruption

If the clamping motion is interrupted by releasing the cut buttons, breaking the light beam of the light
barrier or power failure, both ball valve and conical valve become deenergized. By this the clamp is
stopped immediately at the present position i.e., the lower clamp edge remains below the knife edge.

If after the cutting has been interrupted, is necessary to have a down movement of the clamp, than in
actuating the foot pedal a contact of switch S309 energizes the conical valve Y315 allowing the clamp to
move down as done in the function "Mechanical Cutting Line Indicator".
The return of the clamp to the upper resting position takes place after the cut cycle is completed and the
knife is resting in its upper position.

63 Accompanying documentation
Accompanying documentation Reservoir label 1 and 2 channel hydraulics 78

18.02.2000 / ED_99gb3
Y27 Y27 + Y27a

Y315 Y315
64

+5 +5

min. 38 max. 170 bar min. 38 max. 170 bar

 ED_99gb3 / 18.02.2000

Graphic Controller (GC 1)

The 16-bit graphic card GC 1 is linked with CP by means of the SMP bus. It generates the contents of
display for both 10.4" displays. Via the 25-pole plug (RS 422) at the front side of the card the video data
(RGB, HSYNC, VSYNC) are supplied to display adapter ADA_D. Adapter ADA_D is available in two
different versions for plasma panels and TFT displays (see block diagram, page 59).
In the case of the monochrome version the adapter supplies +24 Vd.c. for the additional power supply
unit, in the case of the colour display unit it generates the voltage for background illumination (approx.
450Va.c.).

Graphic card GC 1 is supplied with a voltage of 5 Vd.c., the card is equipped with a processor of its own
(TMS 34010) and a V-RAM of 512 KB as well as a D-RAM of 2 MB. For service purposes the machine can
be operated without video card.
Attention!
The machine type has to be selected as an "S" or "78E" at board CP (dip switch 2).
The functions of the machine can be inspected without display function in such case.

65 Accompanying documentation
18.02.2000 / ED_99gb3

Keyboard Computer KC

The keyboard computer monitors the keys and switches of the keyboard. Any activation of a key or switch
is signalled to the CP - X3 computer via serial interface -X503-.
Keyboard computer KC can be employed with any machine type from 78 S to 176 ED.
The RAM memory located on the board serves for relocating variable data of the program during machine
operation. When the machine is switched off these memories are cleared.
The keyboard computer is supplied with a voltage of 24Vd.c. which is fed to plug X 500 at KC via connector
X 415 of the power module.
The internal operating voltage of 5 Vd.c. is generated on KC from the 24 Vd.c. supplied.
The voltage is indicated and monitored by the green LED V6 and the two measuring points P1 and P2 on
that board. The voltage of 5 V at KC is no longer adjustable.
For service purpopses the keyboard and KC components can be separated at the serial interface of CP.
in that case, the machine can be operated manually by means of the handwheel and the cut buttons.
The keyboard test already known from the monitor machines has been taken over.

A message of stage is given by the speaker of the KC board:

Beep function

1x KC active
3x Communication between CP and KC is trouble free
10 x Graphic controller is not recognized (not 78 ED)

X2 X1
NT 1 AL.T
*
X522
ADA_D dial 1
Plasma - 640 x 480 * BDF
TFT - 640 x 480
DNT dial 2

FKT

X524 X523 X515 X514 X513 X512 X511

X507 X508 X500 X501 X502 X503 X509

KC

X415 X3
+24V / 0V X2

CP GC 1

Power Modul

SMP - Bus

Accompanying documentation 66
 ED_99gb3 / 18.02.2000

Indicators, Plugs and Keys on KC

+ + + +

X507 X508 X500 X501 X502 TEST X503 X504 X505 X506 X509 V1 V2 V25 P1V6 P2

P1 = +5V S1
P2 = 0V
KC
J1 Flash-Eprom V6 = +5V

J2
RAM
X510

LED V1 Computer active, flashes every second during operation

LED V2 lights up when keyboard test has been started, V1 is off at that time
LED V6 indicates operating voltage of +5 V for KC
LED V25 lights up during data exchange between PMS card and KC
Key S1 Start keyboard test
Jumper J4 Connection of external LED for indicating data exchange PMS / KC
Plug X Test Jumper plug for keyboard test (parking position)
Plug X 501 Connection for dial - cut correction
Plug X 502 Connection for dial - variations in print
Plug X 503 Serial interface to CP plug X3
Plug X 504 not assigned
Plug X 505 not assigned
Plug X 506 not assigned
Plug X 507 Linkage to DAK (adapter for small display)
Plug X 508 Linkage to ADA_D (adapter for plasma panel / TFT display)
Plug X 509 Linkage to keyboard
Plug X 510 Plug connector for PMS card

Keyboard and Display 78 S - 137 S, 78 E, 78 ES

L CD -
3 5 0 ~ (B ackli ght)
Dis play

240 x 128

20 2

X 518

DA K
X 517

6 4 KB
G1 1 2 8 KB
P MS 3V
R 3
1 MB
X 516

20

X 510 X 507

V25 V6
KC
+5V

B DF /S
X511

X509

K C.P 1

26 +2 4 V
V1 V2 S1

B1 T es t 3 4 5 6 7 8

+24V T es t
X 5 0 0 .1 / 2 .3/4 X 5 0 3 .3 4 5 6 7 8
K C.P 2

P M 4 1 5 .3 .1 CP - X 3 .5 .4 .1 .6

0V +24V

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Keyboard and Display 78 ES

The keyboard and keyboard controller in 78 ES machines is one unit like in the POLAR 66. A slot for a
PMS card is not included. The keybord controller is supplied with +5 V d.c.

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Keyboard and Display "E" 92 - 176 (monchrome)

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Keyboard and Display "ED" 92 - 176 (color)

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Service Information POLAR S, E, ED

SW2.4 OFF SW2.4 ON

If the window service in the main menu is selected, you can enter via code no or with the preselection of
SW2.4 in CPcard into the service mode. There you will find the following overlook.

1. Technical Machine Data

Indication of machine dependent data

2. Alter Machine Data

Adjustment of variable machine parameters.

3. Presetting of Machine
Indication of software version and preset of DIP switches on board CP-2

4. Diagnoses / Test / Check

For the machine check necessary information and support are collected under this menu point.

5. Comment
Menu for storing machine and/or service information

6. Printing
Selection of sub-menues: Print service report, print texts, print text errors (wrong/missing texts)

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Technical Machine Data

Brake afterrun
determines the distance which is covered after the backgauge motor brake has been switched off and
until the backgauge actually stops.

Slow down distance

describes the last portion of the positioning distance, which is covered at minimum positioning speed.
The creepage distance is calculated on the basis of the creep speed measured and a creepage time of
350 ms. (Those machines fitted with parameter step „Smooth stop at position“ when activated allow a
creepage time of 700 ms; this means positioning with twice the creepage distance.)

Backgauge end position

is determined by the position of the rear table limit switch. This measured value which is automatically
determined by the machine in a reference run serves to determine the type of machine for the computer.
The calculated value is the basis of a correct positioning of the backgauge as well as an adequate selection
of the menu guided knife change by the computer.

Reference position
The three measurements are composed of the electrical and mechanical reference points, (pulse generator
and switch B 341). The first and the last value is generated by switch B 341 with the corresponding
operating flag. (signal sequence „0-1-0“).
The middle value which is designated as reference point of the pulse generator,, is output upon every
rotation of the spindle (= 10 mm backgauge forward feed). To detect the reference point which is important
for backgauge positioning the machine requires the following condition to be met:
a.) Switch 341 is supplied to Psignal by the operating flag.
b.) the pulse generator must also generate a reference point during this phase. The value should be as
close as possible to the centre of the High phase of switch B 34 1. The value can be corrected by moving
the operating flag. Once the conditions have been complied with correctly LED -V2 - of CP2 will indicate
the AND logic of the signals by lighting up briefly.

Max. speed
The maximum advance speed of the backgauge drive unit obtainable in automatic operation. The basic
adjustment is made at the frequency converter for the backgauge motor. The setting of the frequency
converter requires a keyboard unit lid. no. 229709). This service tool can be purchased from the Polar
Spare Parts Department. The adjusting values for types 79 and 92 are approx. 45 Hz, which corresponds
to a forward feed of approx. 20 cm/s. On machines as of type 115 the frequency is set to approx. 65 Hz or
approx. 30 cm/s.

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Creep rate
The creep speed is the minimum positioning speed for the backgauge drive unit to be adjusted at the
frequency converter. It is approx. 2 Hz. It must be observed, however, that the motor being adjusted in this
way should be left sufficient torque to position a particular measure. Attention must be drawn to possible
mechanical stiffness in the area of the backgauge drive unit. The optimum value of Vmin is approx. 3.0%
of V max.

* after any modifications of the frequency converter a new reference run must be performed prior to a new
function test.

Cutting time „OT - UT / UT - OT“ (OT = TDC) (UT = BDC)

Both measuring values taken together result in the actual knife operating time for the complete cut. The
first measuring value „OT - UT“ designates the time passing between the activation of magnetic valves
Y33/Y33a and frictional connection of main clutch until knife upstroke control recognizes the „electrical
UT“ and sends a signal to the computer.
The second time value „UT- OT“ is calculated from the detection of the electrical UT until signal change
UT (>not UT <) is recognized by the computer. Once the signal has been recognized the knife movement
is switched off and the knife will come to a standstill at the mechanical upper dead centre with the respective
afterrun.

Knife reacting time

The time delay between energizing of the magnet valves (or clutch in machine 78) and the moment of the
first recived counting pulses from the MHS95 is displayed. The maximum tolerance is different depending
the software versions. In case of machine faults see the remedy in the list error explanations (Fehler 608).

Knife positions at UDC & BDC

The position of the electrical switch points UDC (OT) as well as BDC (UT) on the circle of the crankarm.

Knife Afterrun Tolerance (only visible if SW2.4 is in position ON)

The indicated values, i.e. times and angles, are the max. admissible limit values, before the computer will
output an error message on the display locking clamping and cutting. Prior to a permanent lock-up of the
cut there is a so-called „warning threshold“ -

Machine Warning Threshold Max. Value

78 and 92 100 msec. / 20 degrees 120 msec. / 25 degrees

>= 115 120 msec. / 20 degrees 140 msec. / 25 degrees

Knife Afterrun (only visible if SW2.4 is in position ON)

The knife afterrun determined by the computer for the respective machine. The two measured values
calculated must be within the tolerance ranges specified in item 9. Any measured value (time/angle)
which is not within the tolerance range will be regarded as an error causing clamping and cut to be locked.

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Alter Machine Data

1. Counter total cuts

Counting of all cuts executed on the machine. This counter is independent from the cutting or preselection
counters available to the operator. When the CP2 board or the battery is replaced the counter of total cuts
shows an indefinite value which should be reset.

2. Accuracy tolerance
Admissible deviation in a positioning process. If the backgauge position selected is within a preset tolerance
range the mesuring display is adjusted to the nominal position stored. As soon as the tolerance is exceeded
error message „position not reached“ is issued and the actual backgauge position is displayed. Values
between 0.008 cm and 0. 1 cm can be stored as tolerances. In the test mode the minimum value can be
set to 0.000 cm* The accuracy allowance adjusted in the factory is 0.008 cm.
(*applies only to a switching-on phase of the machine)

3. Display correction actual position

In standard operation this correction is switched on. This ensures that odd numbers are eliminated for
those cut sizes approached which are within a preset tolerance. As a consequence, the operator will
always read identical nominal and actual positions on the display. If the correction has been switched off
for testing purposes it will be reactivated automatically after the machine has been restarted.

4. Display type
This setting option is only provided for internal testing. This issue of the menue will not be available any
longer in the succeeding version of V 1.3.0. The factory setting in program versions up to V 1.3.-d, i.e. „ 1
„ or „2“ for different types of TFT-displays.

5. Machine number
Here you can enter (store) the machine no.

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Presetting of Machine

The preselection on the CP-board as well as the software versions of the components are displayed in the
presetting of machine. The variation of presettings are discribed under DIP-switches SW2 and SW3 on
CP-Board.
Also the software versions of CP-Board, graphic controler and keyboard controler are displayed.

Diagnosis / Test / Check

For the diagnosis helpfull functions are selected in seven groups

1. Error messages
2. Backgauge position check
3. Input / Output check
4. Measure clamp moving time
5. Checking of position counter chip
6. Check of knife gearing
7. Trace of knife position

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Error messages

Any faults during operation of the machine are displayed in the screen and stored with time and date. Only
the last eleven messages are shown Earlier messages are deleted but the numbering continues. There is
the following rule. If the same message comes up again, time and date are replaced only. An other error
shows a new message.

Backgauge position check

The machine control observes always the backgauge position. Deviations between nominal position and
actual position are displayed in three different messages.

Max. error after positioning

A comparision of nominal and actual position is done during each backgauge positioning. The
result is always used as a correction of the backgauge afterrun and is also an information for the
service technican. The display shows the maximal correction value ever need after the last zero
resetting.
Max. position error at standstill
The position is checked during the standstill of the backgauge too. If the control observes a change
(i.e. during a hard knock up of material) the operator will be informed to position the backgauge
again. Also here the maximal deviation after zero resetting is stored and shown.
Max. error at reference position
The value of the reference point stored in the memory is compared to the value of the position
counter every time the reference point is passed over. Any deviations are written into the error
memory before the measuring indication is updated. The value stored will always be replaced by a
higher one.
Should there be any deviations below the value stored such values are not indicated.
1. Reset max. position error
By means of this function the „max. error of pos. counter“ value displayed in the „machine data“
image is reset to >0<.

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Input Output check

Indication of inputs and outputs in the cutting cycle and backgauge drive unit for limit switches,
magnetic valves and light barrier.

Measure clamp moving time

For a better adjustment of the dynamic force of the clamp during use of the pedal the clamp speed can be
measured.

Press pedal during the display "measuring clamp moving time" and in the moment when the clamp touches
the table surface press any number key. Magnetic valve Y315 locks the clamp down and the display
shows the lowering time in milliseconds.
Another pressing of any number key let energize magnetvalve Y315 again and proximity switch B29
observes the upper position and displayes the lifting time in milliseconds.

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Check of knife gearing

(in german
language only)

Knife Path OT - UT
is the distance/time covered from the initial point (knife in mechanical upper dead centre) to the electrical
lower dead centre. Time measurement is started with the first pulse of the knife upstroke control registered
by the computer.

Knife Path UT - OT
once the electrical lower dead centre has been recognized the distance and time needed to reach the
electrical upper dead centre is determined.

Eletrical switching point "Not - UT"

Switching point of NOT - UT signal to computer

Mech. lower dead center measured (not used)

Knife Afterrun
is the distance covered at the electrical UDC after knife drive unit (Y33 + Y33a) is switched off, until
the knife has come to a complete standstill. if the knife afterrun exceeds the admissible tolerances the
operator will be informed by an error message (refer also to page 3).

CUTTING SPEED EMPTY (i.e. without material)

CUTTING SPEED LOADED (i.e. with material)
at present these data is only determined in connection with cutting optimization option.

Upstroke Speed
Indication of knife return speed in degrees per second

TV Knife Bar Lock-up

the time necessary after activation of SB magnet to lift the safety lever from lock-up position to unlocked
position. Both conditions are scanned by a sensor, each. If the maximum admissible time has been
exceeded (e.g. due to stiffness of machine) the cut will be locked and an error message output.

TV Magnetic Valve/Clutch
is the time period between activation of magnetic valves Y33 and 33a and start of knife movement.
Consequently, this time frame includes also the setup of the clutch pressure and the reaction time of the
main clutch.

Actual Knife Position

The actual knife position reached after the end of the cut. The second indication of counting pulses
includes nominal and actual counter. The presetting of 240 pulses corresponds to a complete movement
of the knife. The actual counter is cleared after every cut.

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Trace of knife position

This menu item is meant for switching the control counter of the knife movement on or off.
One complete knife movement OT - OT corresponds to 240 pulses. The counting pulses registered are
displayed in mask „knife clutch control“. Once the cut has been released the pulses received within 500
ms from the computer must be recognized by the knife upstroke control system. If this waiting period
is exceeded, e.g. due to mechanical stiffness knife movement will not be initiated and error message
„knife pulses counting error“ is output. When the cut has been started the computer expects one positive
counting pulse every 10 ms at the least. Otherwise, the knife movement is stopped and the above mentioned
error message is output. For safety reasons, as of program version V - 1.4 the control function can no
longer be switched on/off for service purposes. As a consequence, the monitoring function remains
permanently active.

Remarks

Remarks for service purposes can be stored here. This can be supports for service activities later on or
an information about finished jobs.

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Overlook of adjustments and check values

1. Mechanical
78 92 115 137 155 176

Gap for knife carrier 0,05 0,05 0,05 0,05 0,05 0,05
Gap between
clamp and knife 0,25-0,3 0,25-0,3 0,3-0,35 0,3-0,35 0,3-0,35
Clutch gap 0,2-0,4 0,4-0,8 0,4-0,8 0,4-0,8 0,4-0,8 0,4-0,8
air gap (iron / iron gap)= clutch gap +0,1 mm
min. size for brake and
clutch shoes 1 mm 1 mm 1 mm 1 mm 1 mm 1 mm
Basic assembling of turn
buckle nut (old knife change) 2 top 4 bottom 4 bottom 1,5 bottom
Gap for backgauge
motor brake 0,2 0,2 0,2 0,2 0,2 0,2

Pos. of limitswitches in mm
Front limit screw 16 19,5 19,5 20 29,5 29,5
Front limit screw by swivel backgauge. 21,5 22 29,5 29,5
S7
S8 68 88 88 88 118 118
S9 18 24 24 24 34 34
S13a
S13 935 1165 1465 1565 2015
Rear limit screw 945 1175 1475 1575 2025
Smallest cut in cm 2,5 2,5 2,5 2,5 3,5 3,5
with false clamp in cm 7 9 9 9 12 12
Max. ream height in cm 12 16,5 16,5 16,5 16,5 16,5
Weights
Machine in KG 1300 1890 3200 4120 4950 5850
Frame
Table
Gearbox
Knife thickness in mm 11,7 11,7 13,75 13,75 13,75 13,75

2. Hydraulic
78 92 115 137 155 176

Safetypressure 1 12 17 17 16 20 20
Safetypressure 2 17 22 22 21 25 25
Safetypressure 3 <30 <30 <30 <30 <30 <50
Min. clamp pressure 38 30 34 33 34 34
Max. clamp pressure 155 115 102 125 135 135
2200 3500 4500 4500 6000 7000
Clamp lowering time
by using foot pedal 1,2 1,8 1,8 2 2
Clutch pressure 60 70 75 90
Hydraulic system
Oil quantity in l 6 17 33 33 33 33
Gearbox
Oil quantity in l 0,7 1,2 1,6 2,5 2,5

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3. Electrical
78 92 115 137 155 176

Fuses
F 1 AC-IN 6A 6A 6A 6A 6A 6A
F 1 AC-IN 6A 6A 6A 6A 6A 6A
F 3 AC 1,5A 1,5A 1,5A 1,5A 1,5A 1,5A
F 4 AC 10A 10A 10A (16A) 10A (16A) 10A (16A) 10A (16A)
F 5 AC 2A 2A 2A 2A 2A 2A
F 6 AC 2A 2A 2A 2A 2A 2A
F 7 DC 4A 4A 4A 4A 4A 4A
F 8 DC 5A 5A 5A 6A 6A 6A
F 9 DC
F10 DC 6A 6A 6A 6A 6A 6A
F11 AC-IN 1AT 1AT 1AT 1AT 1AT 1AT
F12 ST-I 1AT 1AT 1AT 1AT 1AT 1AT

Jumper FU 1-2 1-2 1-2 1-2 1-2 1-2

C001 0 0 0 0 0 0
C007 0 0 0 0 0 0
C008 9 9 9 9 9 9
C010 2 Hz 2 Hz 2 Hz 2 Hz 2 Hz 2 Hz
C011 45 Hz 45 Hz 60 Hz 60 Hz 60 Hz 60 Hz
C012 0,05 0,05 0,05 0,05 0,05 0,05
C013 0,05 0,05 0,05 0,05 0,05 0,05
C014 0 0 0 0 0 0
C015 50Hz 50Hz 50 Hz 50Hz 80Hz 80Hz
C016 8-15% 10-20% 10-20% 10-20% 10-20% 10-20%
Brake afterrun 0 - 0,10 0 - 0,10 0 - 0,20 0 - 0,20 0 - 0,20 0 - 0,20
Slow down travel
Backgauge speed. max: 20 cm/sec 20 cm/sec 27 cm/sec 27 cm/sec 27 cm/sec 27 cm/sec

Offset Board SAP 0,0V (+/- 0,1V)

Signal from SAP to FU forward backward

Volt Hz Volt Hz
slow by keyboard 2,6 18 2,6 18
S10, S14 5,3 35 5,3 35
Positioning 10 65 10 65
Reference run
in front of ref.-point 2,9 19,5 1,2 8,5
behind of ref.-point 2,9 19,5 1,2 8,5

+24 V 23,7 - 24,3 V

+12 V 11,4 - 12,6 V
+ 5V 5,08 - 5,12 V

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List of LED´s

LED Colour Meaning Basic condition

Kimodul
ME green Motor start-up (flashing during start-up) OFF
MH red Upstroke terminated ON

K1T
yellow Motor start-up (flashing during start-up) OFF

KAP
V8 green +24V d.c. power supply KC ON
V9 green +45V d.c. power supply PS 95 ON
V10 green +24V d.c. power supply for MHS (2 channels) ON
V11 green +8V d.c. power supply for MHS (SAP) ON
V12 green +25V d.c. power supply for valves ON

PS95
V1 green +24V d.c. ON
V2 green +12V d.c. ON
V3 red Reset OFF
V4 green +5V ON

CP2
V1 red Computer is activ ON
V2 yellow Reference point (flashes during scanning of reference point) OFF
V11 green Down-load OFF
V12 green Down-load OFF
V13 green Down-load OFF
V14 green Down-load OFF

SKÜ
PR red Clamping active OFF
MS red Cutting active OFF

LS
D1 red State ON
D2 red State ON
D3 red State ON
D4 red State ON
D5 red State OFF
D6 red State OFF

KC
V1 red Computer active flashing
V2 red keyboard test active OFF
V6 green power supply ON
V25 red lights up during data exchange between PMS card and KC OFF

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LED Colour Meaning Basic condition

SAP
V29 yellow UT1(lower dead centre) of MHS 95 OFF
V28 „ OT1(upper dead centre) of MHS 95 OFF
V27 „ UT (lower dead centre) of MHS 95 OFF
V26 „ OT (upper dead centre) of MHS 95 ON
V6 red Backgauge motor brake Y17 on (free) OFF
V5 yellow End posit. at front, with false clamp plate and Fixomat OFF
V4 red not used OFF
V3 „ Control signal backgauge return for frequency converter OFF
V2 „ Control signal backgauge advance for frequency converter OFF
V1 „ Enabling signal for FU* OFF
V25 yellow 0° signal from MHS 95 ON/OFF
V24 „ 90° signal from MHS ON/OFF
V23 „ Limit switch front (S9) ON
V22 „ Fixomat active OFF
V21 „ Limit switch rear (S 13) ON
V20 „ Handwheel precision adjustment (S 18) OFF
V19 „ " (S 14) OFF
V18 „ " (S 10) OFF
V17 „ Pedal switch (S390) OFF
V16 „ False clamp detection 3 (S 218b) OFF
V15 „ False clamp detection 2 (S 218) OFF
V14 „ False clamp detection 1 (S 6) OFF
V13 „ Limit switch front slowly (S 7) ON
V12 „ Limit switch rear slowly (S 13a) ON

Freqency Converter
V1 red Error OFF
V2 green stand by (active during backgauge movement) flashing

SK
V83 red Safety lever (YSB) OFF
V84 „ Output for cutting circuit transformer (XFMR - press.- on SKÜ) Y27, Y27a OFF
V85 „ Light barrier test terminated positively OFF
V86 „ Cut buttons actuated correctly (within 0.5 sec.) OFF
V87 „ Control signal for safety lever (nomin. condit.) OFF
V88 „ Logic error in cutting circuit (reset) OFF
V89 „ Output for cutting circuit transformer (XFMR -cutting- on SKÜ) (Y33, Y33a) OFF
V71 yellow Safety lever in blocking position (B SB e) ON
V72 „ Safety lever unblocked (B SB a) OFF
V73 „ NC contact right-hand cut button ON
V74 „ NC contact left-hand cut button ON
V75 „ NO contact right-hand cut button OFF
V76 „ NO contact left-hand cut button OFF
V77 „ Knife upstroke (UTH = lower dead centre upstroke) from SAP OFF
V78 „ Knife descending (UTH neg.) from SAP ON
V79 „ Clamp at upper position (B29) ON
V80 „ spare OFF
V81 „ Pedal switch (S309) OFF
V82 „ „Table air“ key „ON“ OFF

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Last changes of this file

Version Date Changes

ED_99e1_ 14.01.1999 general revision KMei

ED_99e2_ 05.03.1999 text corrections
Layout for international paper sizes KMei
ED_99gb3_ 18.04.1999 New drawings and changings about V4.0 included KMei
ED_99gb3_ 18.02.2000 Software-versions "-13" added KMei

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