Polar EMC1

Das Polar-Service-Handbuch 3 gilt fiir alle POLAR EMC ab Baujahr
1978.
Es darf such auszugsweise weder nachgedruckt noch vervielfaltigt werden und es ist nicht gestattet,
dieses Handbuch an Dritte weiterzugeben oder zu entleihen
(5 15 d. Ges. vom 19. Juli 1901 und § 18 d. Ges. vom 7.Juni 1906).
The Polar-Service-Manual 3 is valid for all POLAR EMC machines

beginning 1978.
Reproduction in print, photo copy or any other method is strictly prohibited. The manual should not be
handed over or lent out to persons outside the POLAR-organization.
Dieses Handbuch ist die Arbeitsunterlage fur den gesamten POLAR EMC-Service. Sie enthalten eine
detaillierte Beschreibung aller erforderlichen Handgriffe und erleichtern lhre Arbeit dadurch wesentlich.
This is the fundamental reference book for the whole POLAR EMC-service. It contains a detailed
description of all necessary information for fitting and servicing POLAR cutters. Your job willbe very
much easier if you follow this instructions.
Printed inGermany
ND 100374826001
Index 1
INDEX OF SERVICE MANUAL POLAR 1151155 EMC

The single positions you will find either in the EMC service manual 3or in the CE/CS service manual 2 under the numbers
mentioned below:
Service manual 3 Service manual 2
1.0 Assembling Instructions
1.1 Packing
Inland packing ............................................. 1.1.1
Export packing ............................................. 1.12
Unpacking of the export case ..................................... 1.1.3
Moving of the frame .......................................... 1.1.4
Moving of the table .......................................... 1.1.5
Erection and positioning of the frame .............................. 1.1.6
Pedalforclamp ............................................. 1.1.7
Fitting of the table ......................... 1 .I .20
Table wire connections ........................................ 1 .I .9
Main power line connection ..................................... 1.1.10
Mainmotor ............................................... 1.1.11
Light barrier ............................................... 1.1.12
Backgauge assembling ......................................... 1.1.13
Rake assembling ............................................ 1.1.14
How to insert the cutting sticks .................................. 1.1.15
How to insert and adjust the knife ................................ 1.1.16
1.3 Hydraulic system

partly ................................................... 1.3a-e
1.5 Machine testing and checkout

Parallel cut ................................................ 1.5.1
TableMotor ............................................... 1.5.2
General Testing ............................................. 1.5.3
2.0 Description of functions

2.1 The gear
Gear limit switches ........................................... 2.1 .I
2.2 The Clutch

Hydraulic clutch ....................... : .................... 2.2.1
2.3 The machine hydraulics

Hydraulic control ......................... 2.3.10
Hydraulic pump ............................................ 2.3.3
Working cylinder ............................................ 2.35
Sliding valve ............................................... 2.3.6
Fixing plate ............................................... 2.3.8
Special Accessories ........................................... 2.3.9
2.4 TheClamp ................................................ 2.4
2.5 The Knife Carrier

Overload Safety Device ........................................ 2.5.1
Theknife ................................................. 2.5.2
2.6 The Table

The table spindle ............................................ 2.6.1
The table motor ............................................ 2.6.2
The backgauge brake ....................... 2.6.10
Hand Fine Adjustment ........................................ 2.6.4
Slide .................................................... 2.6.5
Backgauge ................................................ 2.6.6
Backgauge rake ............................................. 2.6.7
index 2
2.7 Optical Cutting Line Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. , . . . 2.7
2.10 Measurement system

Fitting of linear measurement system . . . . . . . . . . . . 2.10.1
2.11 Summary of test works

Testspecification 115 ....................... 2.11.1
Test specification 155 ....................... 2.11.2
Adjustment of reference measurement ............ 2.1 I.3
Check of spindle play ....................... 2.11.4
Check of adjustment of table limit switches ........ 2.115
3.0 Electrical Equipment

3.1 Structure of control POLAR 115/155 EMC
Main connection .......................... 3.1 .lO
Master switch and star-delta switch .............. 3.1 .I 1
Star-delta switch automatically ................. 3.1 .I 2
Main motor ............................. 3.1.13
Main distributor .......................... 3.1 .I4
Control transformer I and I I ................. 3.1 .I 5
Adaption of the control to the incoming voltage ..... 3.1 .I6
Power supply part (P-part) ................... 3.1 .I 7
Plug-in card la ........................... 3.1.17.1
Plug-in card 2a ........................... 3.1.17.2
Plug-in card 3a ........................... 3.1.17.3
Plug-in card 4a ........................... 3.1.17.4
Control part D (D-part) ..................... 3.1 .I 8
Base plate ............................... 3.1.18.1
Plug-in card 5 ............................ 3.1.18.2
Plug-in card 6 ............................ 3.1.18.3
Plug-in card 7SB .......................... 3.1 .I 8.4
Plug-in card 8 ............................ 3.1.18.5
Plug-in card 8c ........................... 3.1.18.6
Plug-in card 9 ............................ 3.1.18.7
Contactor part C (C-part) .................... 3.1 .I 9
Plug-in card 22 ........................... 3.1.19.1
Control panel ............................. .3.1.20
Push button plate N-T I ...................... 3.1.20.1
Push button plate N-T II ..................... 3.1.20.2
Push button plate N-T III .................... 3.1.20.3
Push button plate N-T IV .................... 3.1.20.4
Assembly potentiometer ..................... 3.1.20.5
Measurement scale MA2 I and II ................ 3.1.20.6
Backgaugestopdisplayand measurementdisplay ISA I and I I 3.1.20.7
Plug-in card Cassette-interface N-Cl .............. 3.1.20.8
Plug-in card interface N-l ..................... 3.1.20.9
Plug-incardalterationofmeasurementandgrippermarginMAV3.1.20.10
Plug-in card keyboard N-KB .................. 3.1.20.11
Plug-in card central unit N-CPU ................ 3.1.20.12
Plug-in card counter N-Z ..................... 3.1.20.13
Plug-in card automatic knife and special function N-MS 3.1.20.14
Plug-in card Fixomat N-F .................... 3.1.20.15
Interchangeable memory unit N-DS .............. 3.1.20.16
Linear measurement system ................... 3.1.30
Adjustment of reference measurement ............ 3.1.30.1
Investigation of rake position .................. 3.1.30.2
Index 3

3.2 Description of functions
POLAR 115/155 EMC ...................... 3.2.10
Forward movement of backgauge on Standard operation 3.2.10.1
Reverse movement of backgauge on Standard operation 3.2.10.2
Backgauge forward- and reverse movement slow
on Standard operation .................... 3.2.10.3
Backgauge brake on Standard operation ........... 3.2.10.4a
Backgauge brake on automatic operation .......... 3.2.10.4b
Non repeat device ......................... 3.2.10.5
Light barrier amplifier ...................... 3.2.10.6
Timing device control ....................... 3.2.10.7
Cutting circuit ............................ 3.2.10.8
Safety bolt .............................. 3.2.10.9
Conical valve control (Pressure clamp) ............ 3.2.10.10
Automatic knife .......................... 3.2.10.11
Air table control .......................... 3.2.10.12
3.11 Survey of tests

Instruction for voltage regulation ............... 3.11.1
Voltage of disconnected control panel ............ 3.11.2
Machine with MATE-N-LOK plugs .............. 3.11.2.1
Machine with central plug .................... 3.11.2.2
Measurement on power supply part (P-part) ........ 3.11.2.3
Voltage of connected control panel .............. 3.11.3
Check of bonding - 0 volt ................... 3.11.4
Lamptest ............................... 3.11.5
Test afterrun of brake ....................... 3.11.6
Test of interchangeable memory unit ............. 3.11.7
Store of actual size ......................... 3.11.8
Putout of memory program .................. 3.11.9
Test of rake position ........................ 3.11.10
Test of numerical key board with calculation ....... 3.11 .I 1
Test of special funktion key ................... 3.11.12
Test of memory ........................... 3.11.13
Testreport 115plug64,68 ................... 3.11.14
Test report 115 central plug ................... 3.11.15
Test report 155 ........................... 3.11.16
1.0 - 1.1.20
.O ASSEMBLY INSTR
1.1.20 Table Erection

Before table erection takes place the machinetframe) has
to be hooked up to the power line.
See Service manual 2 1 .I .I0 Main Power Connection
1 .I .I 1 Motor Hook Up
After machine has been hooked up correctly, turn on Main
switch. A short touch on the foot pedal will bring the
clamp to its upper position and the table can be moved
into the frame.
2.0 - 2.3.10
2.0 Description of mechanical functions Machines of type 92,115 and 155

The complete Hydraulic System is installed within the right
2.3 Machine Hydraulic frame pillar and the inside of the pillar itself istheoil tank.
The Hydraulic System of the POLAR Models 92 - 115 -
2.3.10 Hydraulic 79 Control System 155 consist of a double stage vane type pump, a hydraulic
The Hydraulic System has been changed in such a way that control block, a hydraulic working cylinder, a 5-way value, a
now the Safety Pressure of 50 daN is maintained within piston-cylinder in the gear unit a retarding device inoil line
the total movement of the clamp. P2K by POLAR 92 and 2 retarding devices by POLAR 115
Additional, the clamp will remain stopped in any position - 155 in oil line PI and P2K respectively. .
during a cut interruption and the Safety Pressure of 50 If the machine is turned on, the hydraulic pump will pro-
daN stays on. vide oil flow from PI and P2, tothecontrol blockand with
In order to achieve the exact Safety Pressure it became ne- a circulation pressure of 1 - 2 bar back to the oil tank.
cessary to reduce the speed of the clamp movement. The Pushing in the two cut buttons will result in the opening
following datas, within the full movement of the clamp, of the conical valve on the hydraulic control block to clear
have been established: the oil flow from PI to the hydraulic cylinder.
POLAR 92 from 1 ,I - max. I,5 sec. At the same time the ball type valve in the hydraulic con-
POLAR 115- 155 from 1,9 - max. 2,0 sec. trol block will close, enabling the oil pressure in the hy-
Up to now the Safety Pressure of 50 daN was only of a draulic system to build up to the proper level. The piston,
static value without consideration of the Dynamic Power which is pretensioned by a spring, will be moved to its full
from the clamp itself which amounted to a higher value. extend by the oil flow of P2 after reaching 45 bar pressure
The most important changeswithin the new Hydraulic took and at the same time the ball valve will lose. This will start
place at the Hydraulic Control Block (with mounting Base the clamp action from the oil flow of PI and the retardes
the Hydraulic Piping Layout and the Reverse Spring of cutting cycle from oil flow of P2K.
the KINEMATIC Assembly. Clamp action and cutting cycle only can take place after
The exchange with the old type of Hydraulic is not possible. the ball type valve PI has been opened and the ball type
In order to prevent any mistake in the use of the Hydrau- valve of the control block as well as the ball type valve in
lic systems we have marked the Hydraulic 79 with a blue the piston are closed.
paint. The sequence of the happeningswithin the pistonisarranged
Changes within the Hydraulic Control System 79. in such a way that first the clamping pressure from PI is
The second ball valve solenoid has been replaced by a co- being applied and only there after the clutch action through
nical valve solenoid. This conical valve solenoid has the P2K oil flow can take place.
function to stop the oil inflow to the hydraulic cylinder Within the POLAR models 92 - 115 - 155 an additional
when the solenoid is not energized and therefore prevents retarding device has been put into P2K for the purpose of
any movement of the clamp. giving the clamp a certain head start to assure the full pres-
We could omit the second ball valve solenoid since the me- sure of the material to be cut when the knifeaction begins.
chanical safety bolt will prevent any unintentional cycle Hydraulic Pump:
of the knife barrier. On POLAR machines we are using vanetype pumps which
An improved safety has been received by adding an additi- are typical for their relative simple construction and a ge-
onal Hydraulic Safety Bolt to the clamp system. The safe- neral low noise level.
ty pressure valve within the Hydraulic Control Block has The pump is mounted to a flange unit which is then moun-
to be adjusted to the following value: ted to the outside of the right frame pillar.
92 11,5+0,5bar Paper Gaskets (Abil Material) are provided within the
(see drawing)
115/155 14 + 0,5bar pump and flange and within flange and mounting area on
On machines POLAR 92/115/155 there are 2 retarding the pillar to prevent oil leakage. All mounting screws on
devices necessary: the outside flange unit have copper washers under their
a) for knife retarding in oil line P2K heads to assure a sealing off. These screws are accesible af-
b) for clamp (shooter down start) in oil line PI ter removing the main clutch guard and the pump pulley.
Additional an oil quantity distributor device for the clamp On POLAR Models 92 - 115 - 155 the hydraulic pump
speed has been installed. has 2 separate oil pump stages PI and P2, but both stages
The additional reverse block value makes it possible to bring are using the same filter unit for their oil inflow.
the clamp down (Safety Pressure) with the foot pedal. The pump is located below the hydraulic oil level and is
Changes within the Hydraulic Piping Layout: being driven by a V-Belt connection to the main motor. It
Hydraulic Piping Partial rearranged. is very important, to prevent the pump from ever running
Change of reverse spring: dry as this will result in a freeze up of the pump and des-
The reverse spring has been redesigned within the tension troying it. It is likewise important to observe the correct
capability. rotation as otherwise the pump will also fall very shortly.
In order to achieve the correct safety pressure (50 daN on The correct rotation of the main motor is in a clockwise
the clamp) an adjustment on the reverse spring of the Ki- direction (to the right) when viewed from the drive side
nematic can be made. One (1) turn means approx. 2 - 3 and should be checked with the V-Belts removed. (See rota-
daN on the clamp. tion arrow on main clutch guard.) After installing theV-Belts
make sure to have the correct belt tension.
2.3.10
It is very important to bring the hydraulic pump under load Testing and check out procedures:
as soon as the machine is turned on. This will assure that Connect manometer gauge to the check point outlet nipple
all parts inside the pump will receive immediate lubrica- on the right side pillar. (See Service Manual 1.3 Hydraulic
tion. In order to load up the pump, theclamp should be mo- System.) Bring foot pedal down and read scale on gauge.
ved a few times by using the foot pedal or a number of For adjustment of the safety pressure remove cap nut (I)
cutting cycles with medium pressure set on the clamp pres- on the control block, loosen up counternut (2) and by
sure scale should be made. using an alien wrench SW6 the correction can be made to
Control Block:
The control block is mounted by 2 bolts to a base plate.
The sealing is accomplished by using of O-rings.
The base plate is mounted to the hydraulic pillar and a
paperseal (ABIL) is used here for sealing purpose. The hy-
draulic pipes are connected to the inside of the base plate
with this kind of arrangement the hydraulic control block
can easily be exchanged without involving the disconnec-
tion of pipes etc.
Mengenteiler ,,c ”
(in AnschluRplatte)
flow governor
(in connection plate)
,,b ”
I, u *au
Within the hydraulic control block the following valves the proper setting. After completion, secure with the coun-
and switching pistons are to be found: ternut again and install the cap nut.
a = Relieve valve for safety pressure Safety pressure by POLAR 92 = 11.5 + 0,5 bar
b = Switching-control piston for clamp movement Safety pressure by POLAR 115/155 = 14 +0,5 bar
c = Ball valve solenoid
d = Main clutch valve
e = Clamp pressure adjusting valve
f = Control slide piston
g = Conical valve solenoid
Relieve valve for safety pressure

The relieve valve for the safety pressure is connected to
the oil line PI and its purpose is to open the oil circulation
as soon as the oil pressure exceeds the pre sat safety pres-
sure level. According to the safety requirements by using
the foot pedal for clamp movements, a pressure of 50 daN
on the clamp should not be exceeded.
2.3.10
Switching-control piston for clamp movement

The control piston plunger is being moved by the foot pe-
dal and the cam arrangement on the linkage. At the same
time fat the very beginning of the foot pedal movement) a
limit switch is being employed to open the conical valve.
The sequence is as follows:
The cam from the foot pedal linkage is pushing the slide
piston inwards who in turn will more or less reduce the
otherwise free oil flow from PI. The oil now is being for-
ced to excape thru the safety pressure valve 92 = 115 +
0,5, 115/155 = 14 + 0,5 bar partial or in full volume de-
pending on the position of the foot pedal.
Ball type and conical type valve solenoids:

On POLARs type 92/115/155 one ball type valve solenoid
is installed in oil circulation P2 and one conical type valve
solenoid in oil circulation of PI within the hydraulic con-
trol block.
Pushing the 2 cut buttons will first open up the conical
valve in line PI to let the oil flow pass to the hydraulic cy-
linder which in turn is bringing the clamp down.
In the full down position of the clamp the aforementioned
conical valve will close and therefore hold the clamp in this
locked position until the knife cycle has been completed
and the knife has reached the top position. Briefly the co-
nical type valve solenoid will open up now and the clamp
of ball type valve in P2 will become closed when both cut
buttons are depressed and the oil circulation of P2 is
blocked.
The cutting cycle can only start if the ball type valve within
the hydraulic control piston isclosed (45 bar pressure nece- Main clutch valve:
ssary). With this condition existing, the clamp pressure The clutch valve, which is a pre set relieve valve, is connec-
over PI and the retarded cut release over P2K takes place. ted to the oil circulation of P2 and its sole purpose is to
open the oil circulation as soon as the clutch pressure is
exceeded.
The clutch pressure data
by POLAR 92 = 65 bar
Testing and check out procedure clutch pressure

Manometer gauge to be connected to the test outlet clutch
line. (See service manual 1.3 Hydraulic.) The pressure
should be checked during the cutting cycle. Any adjust-
ment or correction is done in the same manner as described
under chapter relieve valve safety pressure.
Clamp pressure adjusting valve:

The clamp pressure adjusting valve - actually and adjust-
able relieve valve - is connected into the PI oil circulation
line. The clamping pressure adjustment is done by a foot
pedal on which a read out scale is attached to.
2.3.10
Clamp pressure
by POLAR model 71/72 min. 18 bar, max. 115 bar
by POLAR model 92 min. 32 bar, max. 130 bar
Testing and check out procedure clamp pressure:

Connect manometer gauge to the test outlet on the right
pillar (See 1.3 Hydraulic system).
The pressure can only be checked during the cutting cycles.
Any adjustment or correction is done by turning the valve
housing cap (3) after loosening of ringnut (4).
The max. pressure position is the fixed by a dead end screw
on which the foot pedal will come to rest in the max. po- 2-
sition.
, - ^ n
PI
Control slide piston

PzK
The oil flow of circulation from PI and P2 is controlled
by the sliding piston in the hydraulic control block. The
movement of this piston is given by the hydraulic oil pres-
sure itself and a compression spring holding the sliding
piston down. In the idling position of the machine, the ball
P2
type valve is open and oil from PI and P2 can flow via the
channel grooves on the sliding piston back to the oil tank.
However is the ball type valve closed, then the oil flow
from P2 is blocked and an oil pressure build up in line P2
will take place. Thru a small nozzle opening in the sliding
piston the compressed oil is pushing against the button
surface of the piston. The result is an upward movement
of the piston (against the spring tension) and by 45 bar
the piston has reached the full up movement position. At Stellschraube
this stage the ball type valve becomes closed and the clamp- (Adjusting screw
ing pressure over PI as well as the cutting cycle over P2K
in a retarded timing takes place.
Achtung!
Oil quantity distributor device
Bei Anderung der Abfahr-
The above distributor device is mounted to the connection
geschwindigkeit andert sich
base plate and its purpose is to regulate the clamp speed
such der SicherheitspreR-
on its down movement.
The oil flow is being regulated by a diaphragm mounted druck.
to a sliding valve.
With increasing oil quantity flowing, the diaphragm will Attention!
be pressed toward a spring, resulting then in a decreasing If down speed of clamp is
of its oil outlet opening and therefore regulating the clamp ever changed, then the sa-
movement so that the clamp speed is held at a constant le- fety pressure will change
vel. also.
The pre-setting or adjustment of the clamp speed is done

as follows:
Counter clockwise turning of adjustment screw
= Steuerschieber
clamp speed faster PI
Clockwise turning of adjustment screw (Control valve)
= clamp speed slower
2.6 - 2.6.10
2.6 Table Adjustment of the table brake

1. Compress spring (5) to approximately 45 mm with the
2.6.10 Table brake POLAR 115 - 155 EMC adjusting bolt and secure with lock nuts.
The table brake is mounted at the rear of the table. The 2. Turn spindle (3) to determine the highest spot on the
brake disk (1) is sliding axial on the rear portion of the brake disk. Force brake disk against drive pulley and
spindle and is connected to the spindle (3) by a key (2). adjust air gap of 0,l mm evenly around the circumfe-
The driver pulley (4), supported by a roller bearing, turns rence of the disk. Adjustment or corrections are done
freely on the spindle end. on the 4 threaded studs.
A compression spring (5) forces the brake disk toward the 3. The brake afterrun should be around 0,5 mm. If this is
brake lining of the drive pulley as soon as the brake coil is not the case, a further correction on the spring (5) may
disenergized. Due to the key connection between brake be necessary.
disk and spindle the backgauge is now being driven as soon
as the table motor starts turning.
To accomplish a backgauge stop, the table brake coil needs
to become energized.
Thru the induction of a magnetic field (the iron part of
the table brake system becomes magnetized) the brake
disk is pulled on and is hereby stopped. An air gap of 0‘1
mm between brakedisk and drive pulley should now exist.
The drive pulley turns now freely on the spindle.
0,l mm
----Yu-
2.610 - 2.10.1
Check of the afterrun of the brake on machines with Schnittlinie (cutting line)
/
EPROMs of 7th march 1979 (Date prirted on the EPROM). i/
All machines are equipped with this part, except machines
with inch-measurement system. Machines, which were de- I
livered before 7th March, in the meantime also have been /
/
equipped with the above-mentioned EPROM. I r---Y \
I
On the keyboard plate connect the two right hand contact i-
pins with a test cable. Please run the backgauge to the re-
ference measurement.
Switch on the ,Numerical keyboard‘ q
( )
L--190--b /
Actuate button ,Total number of cuts/Memory recall (ml. /
( 7 3’/ 6L”)
Afterrun distance will be visible in display number of cuts.
Should be 05 - 0,7 mm
Remove test cable.
Check of the afterrun of the brake on machines with

EPROMs of the 6th July 1979 (machines with inch-mea-
surement system.
On the keyboard plate connect the two right hand contact
l---T77 /-----I
pins with a test cable. Bring the gauge to a measurement
by positioning or by means of automatic backgauge.
Actuate ,Memory storing’ (a 1 \ ’ “-t-i/\) tiMeRstab
Actuate ,Memory re-call’ (m)
Afterrun distance will be visible in display number of cuts.
Should be 0,5 - 0,7 mm
Lagerbock
Remove test cable.
support br
By this system it is possible to test the afterrun of brake

Stellschraube (gesich
in each backgauge position, independent of the reference
adjusting screw (secured) Tastkopf
measurement.
scanning head
2.10 Mefhystem
2.10.1 installation of distance measuring system for
POLAR 115 - 155 EMC.
The distance measuring system as a unit is completely in- 3. Pull wires and cables up to backgauge. Use clamps and
stalled on the table. During normal machine errection no brackets to secure cables in such a position that any
additional assembly on this system is necessary. For hand- backgauge movement will not damage same.
ling and shipping purpose a protection guard has been pro- B
vided which has to be taken off after the table is installed
in the frame. If it becomes necessary to exchange a com-
f$
I
plete unit, then extreme caution and delicate handling are
a must.
Dismantling of the distance measuring system (from table)

Disconnect all wiring on the backgauge and remove /
f-----
cable holding clamps and brackets on sledge. Pull cables -
down.
Remove scanning head from holder on sledge.
Remove holding screws from front and rear support
bracket by POLAR 155 the additional center support 4. Use the dephtgauge to establish the distance ,X’ and Y’
screws and remove measure system. from the bracket 5.
Remove the securing plates (only needed during ship-
Assembly of new distance measuring system ment) and use same later on the secure the scanning
1. Backgauge sledge in specific position (See picture with head of the exchanged measuring system.
dimension 190). 5. Move backgauge to the most forward and rearward po-
2. Attach measuring system to front and rear support sition, check the measurement ,X’ and ,Y’, correct if
bracket (by POLAR 155 oneadd.center support). Slide needed and secure.
measuring system carefull until holes in scanning head 6. Only for POLAR 155
are in alignment with holes in holder and secure. Bring backgauge to the center support (6) and check
distance ,X’ and Y’.
2.10.1
i_ Tastkopf
scanning head
It is important to secure the scanning head of the exchanged

measuring system for handling and shipping purpose. When
using the securing plates, it is recommended to take the
threaded holes an the measuring scale within the first l/3
part of the scale housing.
Attention!
It is imperative to check and reset the basic measurement
position. (See adjustment of the reference distance point’.)
in order to reduce wear on the dustcovers due to extreme

dusty working condition, it is recommended to clean and
lubricate the dustcover lips with silicone.
Dichtl ippen
innen mit Silikon saubern
silicone
Beginning with machines of manufacturing year 1979 it

will be possible to exchange the scanning head separately.
A special assembly and dismantling instruction will be gi-
ven in due time.
2.11 - 2.11.3
2.11 Check and test list 2.11.3 Adjustment-Correction of reference point

211.1 Test instructions POLAR 115 EMC Before any adjustment to the reference point is made make
Hydraulic datas should be sure that over-under cut as well as parallel cut have been
oil temperature . . . . . . . . . . . . . . . . 40 - 5ooc set very accurately.
idle circulation pressure . . . . . . . . . . . 1 - 2 bar With the adjustment of the reference point a coordination
idle circulation pressure, lift mounted . . 4 - 6 bar between the actual measurement ,knife cutting edge to
safety pressure . . . . , . . . . . . . . . . . 14 + 0,5 bar rake front surface’ and the digital measurement display
safety pressure lift mounted will be established.
idle circulation pressure + 14 bar Before the upper control box is mounted, a rough mea-
pressure min. . . . . . . . . . . . . . . . . . . . . 30 bar surement alignment regarding the reference point has to
pressure max. . . . . . . . . . . . . . . . . . . . . 115 bar be completed. For this purpose a certain data has to be set
clutch pressure . . _ . , . . . . . . . . . . . . . . 70 bar on the various align switches on the right side of the rear
reverse spring (rough adjustment) . . . . . . 700 mm connection board. This certain data is approx. l/2 of the
Speed of clamp movement: full backgauge movement distance.
down stroke . (quantity divisor) . 1,9 - 2 set On POLAR 155 this would be approx. 77,5 cm
up stroke . . . . (reversing spring) . . . . 0,7 set On POLAR 115 this would be approx. 57,5 cm
Necessary correction to be done with the oil quantity If the reference point was already set and it only becomes
distributor device and the reversing spring. (1 turn on necessary to recheck or for small correction, then this
the tension adjusting screw will bring 2 - 3 daN on rough adjustment procedure is not necessary.
the clamp.) Procedure for the fine adjustment:
Quantity distributor device: A small paper ream of about 3 cm height should be cut on
Adjusting screw turned putward one side. Bring backgauge to a full measurement of 10 cm.
= clamp speed will increase Turn the paper ream around 1800 and after carefull posi-
Adjusting screw turned inward tioning against backgauge, make the second cut.
= Clamp speed will decrease Take measurement with pocket calliper.
Afterrun of knife carrier . . . . . . . . . . . . 125 mm In our sample we find the measurement now 8,385 cm,
Cuts per min. . . . . . . . . . . . . . . _ . . . . . . . . 22 which means that the paper is smaller as we have set the
Safety pressure (dynamic) on clamp . 45 - 60 daN backgauge. Now we have to figure the difference between
the actual cut size and the display read out.
2.11.2 Test instructions POLAR 155 EMC 10,000 cm
Hydraulic datas should be - 8,385 cm
oil temperature _ . . . . . . . . . . . . . . . 40 - 5ooc
idle circulation pressure . . . . . . . . . . . 1-2 bar 1,615 cm
idle circulation pressure, lift mounted . . 4 - 6 bar
safety pressure on the pressure gauge This dimension of 1,615 cm will now be subtracted from
circulation pressure + 16 bar the setting on the align switches. (If the actual cut would
pressure min. . . . . . . . . . . . . . _ . . . . . . 30 bar have been larger, then the difference would be added.)
pressure max. . . . , . , . , . . , . . . . . . _ . . 120 bar 77,500 (Data set in align switches)
clutch pressure . . . . . . . . . . . . . . . . . . . 70 bar - 1,615
reverse spring (rough adjustment) . . . . . 1120 mm
Speed of clamp movement: 75,885 (Final data for align switches)
down stroke . (quantity divisor) . 2 - 2,l set The align switches are now corrected according to the fi-
up stroke . . . . (reversing spring) . . . . 0,7 set nal datas.
Necessary correction to be done with the oil quantity After the correction has been done, move the backgauge
distributor device and the reverse spring. (1 turn on away from this position in order for the correction to be
the tension adjusting screw will bring 2 - 3 daN on effective in establishing the new reference point.
the clamp.) It is adviseable to test cut the new position by cutting 3
Quantity distributor device: equal sizes as described in the service manual.
Adjusting screw turned putward For correction procedure of the reference point the back-
= clamp speed will increase gauge should only be moved in standard operation.
Adjusting screw turned inward
= clamp speed will decrease
Afterrun of knife carrier . . . . . . . . . . . . 125 mm
Cuts per min. . . . . . . . . . . . . . . . . . . . . . . 21
Safety pressure (dynamic) on clam1 45 - 60 daN Shown setting on the align switches is 077.500
m dm cm mm ‘/Itlmm ‘/lOOmm
2.11.4-2.11.5
211.4 Checking mechanical play of table spindle 2.11.5 Checking procedure of limit switches table and
Push in handwheel until claws of clutch are engaged. Turn false clamp in standard operation
left and right on handwheel until 0,001 mm is visible on (The basic measurement distance has to be established)
digital display of backgauge position. Limit switches on table and position of deadend bolts on
backgauge sledge.
The following chart and drawing will give the position of
the table limit switches and of front and rear dead end
bolts on the backgauge sledge for the various POLAR mo-
dels. All dimensions are given in mm.
C E A = deadend bolt front

B = deadend bolt rear
C = limit switch front
D = limit switch rear
E = limit switch for false clamp plate
I . .
Measures in the disolav
f
TYP
A 1
B C D E
inch mm inch I mm inch mm inch

mm inch mm
;1~c,/67 1385 A6653

I 25 0,981, ' 1180 I&6,&56 90 3,543
, ,
115 23,s j 0,925 1185 i&,653 25 0,984 1180 f&,456 95 3,740
FIXOMAT
155 29,s / 1,161 1 .---

1565 I --I-'
6161L 35 1,377 1560 61,L17 120 L,72L
-
F;XOMAT
155 -‘-‘I”
?? 15 1I l?lR
‘I” IJ 1565 Sl,Sl!, j 35 1,377 1560 61,417 125 L,921
155 2015 79,330 35 1,377 2010 79,133
2m
3.0- 3.1.11
3.0 ELECTRICAL EQUIPMENT The terminals inside the junction box are marked R - S -
3.1 Control System POLAR 115 - 155 EMC T for the 3 phase wires. The terminal for the neutral wire
3.1.10 Main Power Hook Up is marked Mp. In addition a provision is made for aground
The main power line is hoked up to the main junction box or earth hook up with a srew marked , f ‘.
located on the rear of the left frame pillar. Befor connec- If necessary and local electrical codes require a grounded
ting power it is important to check the voltage at the pre- neutral connection then a jumper has to be made between
sent location against the voltage requirements of this indi- the terminal Mp and the ground screw , + ’ within the
vidual machine. machine itself there is none connection between neutral
and ground existing.
+
The individual wires from machine junction box to the
POLAR main switch have the following color coding.
brown Phase
black Phase
black Phase
blue neutral
yellow - green ground wire
Exceptions: CANADA
Phase wires black
5238 Hof heidTwnus
Ground green
180- lx.0 v- 180- LLO v- 180 - ZLOV-
Normally all POLARS are prepared for a 3 phase AC hook

up. The actual voltage can range from 180 - 600 volt with R s T “p SL R s T UP/SL Rsr SL
a 50 or 60 Hz. cycle. It is imperative to observe the local L, L2 L3 N GR L, Lz L3 NlGR L, LI L3 GR
electrical code for the hook up and it is therefore advise-

able to have the work done by a certified elektrician who
should be selected by customer himself. In all circumstances The main junction box is marked on its outside lid with a
a disconnect switch and fuses should be installed in the red lightning arrow, indicating that even with a turned off
power line before entering the machine junction box. The main switch on the machine, power is still on the terminals,
necessary data for size of fuses and wires you will find in if Service within this junction box becomes necessary, the
the following chart. fuses on the disconnect switch should be removed.
VOLTAGE RANGE
3.1.11 Main switch and Star Delta switch (handoperated)
Type of machine 190-240V 34044OV 500-600V The main switch and Star delta switch are located at the
right upper corner of the front frame. In position ,Off’ the
POLAR 175 EMC connection between incoming voltage and machine is in-
Fuses 25A 20 A 20 A terrupted. With the exception of terminals R - S - T in
Wire Size 4 mm2 2,5 mm2 2,5 mm2 the junction box, all other control units on the machine
are without electrical power. The main and Star delta
POLAR 155 EMC switch inside the front frame are covered and here again a
Fuses 35 A 25A 20 A red arrow as a warning sign, marked on this cover, indicates
Wire Size 6 mm2 4 mm2 2,5 mm2 that any work done on this switch requires the disconnect
of the incoming power supply.
The power supply line from fuse box to junction box on The main switch is provided with a lock and key and can
the machine should be kept as short as possible and should be locked in the ,Off’ position. Main switch and Star delta
be arranged in such a way that any damage to thecable can switch are mechanically connected in such a way that the
not occur. ,ON’ position or starting position with the main switch
The POLAR junction box has a connector opening of 28 can only be accomplished when Star delta portion of the
mm permitting the use of piping or conduit as follows: switch is in ,OFF’ position.
Steel pipe: PG 21 However the star delta switch can only be turned on when
American Size Conduit: 314" the main switch is in ,ON’ position.
3.1.11 -3.1.15
Main switch and star delta switch can be turned to ,OFF’ the paper material although the motor speed went down
position separately. Machines equipped with star delta considerably. Naturally it is necessary to take these beha-
switch only, this latter switch takes over the functions of a viors into account and select the paper fusesand wire sizes.
main switch and can be locked also in the ,OFF’ position. We refer to the chart under chapter 3.1.10.
In switching the star delta switch to position ,Y’ the main The main motors itself do not require special service. But
motor will be started. All other machine control units are it is essential to make sure that all air vent openings are
still without power. Switching the star delta switch to the kept free of dust accumulation so that air for cooling pur-
position , n ‘, after the main motor has reached the peak pose has the chance to circulate. Without this small atten-
RPMS, the voltage supply for table light any other special tion any motor has the tendency to overheat and damage
equipment (air blower) is also in the on stage. of the windings will occur. The normal working tempera-
Pushing the button ,Control Voltage on’, located under- tur is approx. 750 C and should not alarm anyone touching
neath the main switch, will feed the supply voltage to all a motor housing by hand, seemingly being to hot. Present
other control units in the machine. The display lights, the modern motors are build to take this kind of temperature.
LS bulbs and the decimal point within the display read out
will be lit up. 3.1 .I4 Main voltage distributor board
The power supply for all control systems are switched thru
3.1.12 Main switch and ailtomatically operated star-delta the main - star delta switch to the voltage distributor board
switch located at the left side of the lower control box. The vol-
Machines equipped with the automatically operated Star tage is fused by 3 10 A fuses.
delta switch have separately from the normal located main Table motor, air blower motor, fluoreszent light for table
switch a double push button device mounted on the upper and control transformer I and II are hooked up after these
right corner front frame for ,ON’ and ,OFF’ position. 3 fuses.
Switch and push button are again covered inside the frame. The control transformers are connected to the power supp-
The Main switch in position ,OFF’ disconnect the power ly by a relay which is electrically switched in by the push
supply and can be locked in this position. After unlocking, button,Control Voltage On’ at the right upper frontframe,
turning the main switch to on position and pushing the after the star delta switch has been turned to position , A '.
button ,ON’, the main motor will start up. Using a relais Turning ,Off’ the machine will also make the relay drop
combination, the motor is connected in star position and off and the transformers are disconnected from the power
after reaching the correct operating speed, the automatic supply.
switch over to delta will take place. The main voltage distributor board makes it possible to
The timing, at which point of motor speed the switch over adapt to the different power requirements of variouscoun-
should take place, is adjustable with a timing device. This tries with specific electrical code rules for fuses and fuse-
feature allows to compensate for any different starting be- holders etc.
havior of the main motors. With the voltage distributor board it is also possible to
After the switch over to delta position took place, a second adapt the machine control voltage in reference to thevari-
push of the ,ON’ button will make the necessary connec- ous incoming power supply.
tion for the power-voltage supply to the control units.
All lights and LS bulbs will light up. 3.1.15 Control Transformers
The Relais combination is mounted on the right inside of Control Transformer I
the lower control box. The control transformer I is located within the left frame
pillar and accesable from the rear.
3.1 .I3 Main Motor For adapting purpose to the various power supply voltages
In position,Y’ the motor will start with reduced power. the primary part of the transformer has taps for 200 V -
This is accomplished with the connection of the 3 motor 220 V - 240 V - and 260 V.
windings as a joint connection on one end. With thisarran-
gement the extreme high but short ampere surge is lowered. The secondary side has the following voltage output.
The motor increases the rotation speed to approx. 1420 ov
rpm. At this stage, noticeable by a steady sound now, 15v Fixomat Drive
the star delta switch is turned to the , A ’ position. In 30 v
this switch position a different connection of the motor
windingsare made, bringing each end of thewinding together ov
with the beginning of the next winding. With this electrical 8V Fixomat-Display
arrangement the motor is capableto deliverhisfull capacity. 16V
All main motors on the POLAR machinery have a special
internal wiring layout, suitable for the needed special mo- ov
-6V
mentum as required by a cutting machine. In other words, 9v
even under very high loads as encountered by cutting heavy
paper stock etc., the motors are not loosing the balance or ov + 24 V
are coming to a standstill. The knife will still be forced thru 32 V
3.1.15 - 3.1.17.1
ov Control Voltage for Relay Coils

If any work is to be done on the machine, the power has
42 V to be disconnected and machine turned off.
Control Transformer II (With Rectifier)
50 v The control transformer II is likewise located within the
25 V For 42 V = DC, Holding Voltage table brake left frame pillar. After removing the front left sheet metal
OV cover, the transformer is accessible from the front.
In addition to the transformer I I, the following components
220 v are mounted on the base plate.
120v Charging voltage table brake Power supply filter capacitor, rectifier with heatsink, screen
ov condenser 22000 mFl25 V and a fuse 10 A to protect the
secondary side of the transformer.
ov The power value of the transformer is 150 VA.
Light bulbs for OS (Optical Cut Indicator)
12,5 V The transformer is furnished on the primary side with taps
for 180 V, 220 V and 260 V power supply hook-up, to
62 v compensate for various voltage conditions within the loca-
5,8 V Light Bulb For Light Barrier lities.
ov The transformer output of approximately 12 V DC is wired
The power value of the control transformer I is 600 VA. to the P-Board to produce here:
All unoccupied taps on the transformer (not being used) 5 V for voltage supply to all integrated circuitries (IC’s)
have insulation sleeves attached. In case of changing con- 5,5 V for voltage supply to the 7 segment displays
nections it is essential to rearrange these insulation sleeves
also, so that in no event any free tap is exposed.
3.1.16 Adaption of Control Voltage to the Main Power

The normal connection between base and plug-in cards is
suPPlY
Main Power Rough Adjust- Final Adjust- Final Adjust- done with male and female type terminal.strips. The con-
ment With ment On ment On nection between the power transistors on the heat sinks is
Plug Connec- Transformer I Transformer II done with flat plugs directly to the front side of cards 2a
tot-s On Main and 4a.
voltage distri- The card 2a should not be put under power without the
butor board power transistor hooked up to the heat sink.
On the base plate, there is a screen condenser mounted for
200V.. . . . 220V.. . . . 200V.. . . . 180V the purpose of additional rectifying the 24 V DC, as well
21ov.. . . . 220v.. . . . 2oov.. . . . 220v as the erasing diodes for the hydraulic lift solenoids.
22ov., . . . 220v.. . . . 220v.. . . . 220v The connections to all other control units are made with
230V.. . . . 220V.. . . . 220V.. . . . 220V plug type connectors located on the front or rear side of
240V.. . . . 220V.. . . . 240V.. . . . 220V the base plate.
250V.. . . . 220V.. . . . 240V.. . . . 260V On the upper right corner of the base plate two 4 m/m test
260V.. . . . 220V.. . . . 26OV.. . . . 260V jacks are provided. The upper one (red) for machine ground
and the lower one (yellow) for potential 0 V.
35OV.. . . . 380V.. . , . 200V.. . . . 18OV The P-Board holds the following plug-in cards:
380V.. . . . 380V.. . . . 220V.. . . . 220V la: Fuse Card
400V.. . . . 380V.. . . . 240V.. . . . 220V 2a: +5v=
420V.. . . . 380V.. . . . 240V.. . . . 260V 3a: + 24 V = and - 6 V =
440V.. . . . 380V.. . . . 220V.. . , . 220V 4a: + 55, V = and + 42 V =
5oovr. . . . 220v.. .*. 220v.. . . . 22OV
6OOV:. . . . 220V.. . . . 220V.. . . . 22OV 3.1.17.1 Card la
Card for fuses and rectifying the holding voltage to table
*Buck and Boost Transformers for control voltage necessary brake.
The fuses have the following functions:
3.1.17 power Supply Eioard (P-Board) Fuse Ampere Voltage Remarks
In general, the P-Board has the function to fuse the secon- 1. lel 2A 120 Vd Charging Voltage for Table
dary side of both control transformers, to deliver a certain Brake
DC voltage and is used also for stabilization of some secon- 2. le2 2A 25 V = Holding Voltage for Table
dary voltages. Brake (derived from 50V )
The P-Board is located in the left portion of the lower con- 3. le3 2A 42 VW Relay Coils
trol panel, between main distributor board and D-Board. 4. le4 4A l2,5 VN O-S Light Bulb
It consists of the base, the card guiding rails for cards la - 5. le5 4A 12,5 VN O-S Light Bulb
2a - 3a - 4a and the heat sinks which are placed left and 6. le6 4A 5,8 Vd L S Light Bulbs
right from the card guiding rails. 7. le7 4A 5,8 VN L S Light Bulbs
3.1.17.2 - 3.1.18.3
3.1.17.2 Card 2a Stabilized Voltage + 5 V To control the continuation of the - 6 V, an automatic

The stabilized voltage of approximately 5 V (approximate- voltage control system is added to the circuit.
ly 4 A) is used to supply power to the integrated system In case of an interruption in the - 6 V supply, automati-
in the upper control panel. The control transformer II in cally the 24 V will be cut off to prevent any malfunction
this instance is the source of the voltage supply. of the machine.
The stabilization is accomplished in conjunction with the Both voltages are fused on the input stage with 0,5A (-6V)
power transistor which is mounted on the left side heat and 4 A (+ 24 V).
sink.
The 3 connection wires are plugged to the front portion of 3.1.17.4 Card 4a Rectification for + 42 V
card 2a and it is emphasized that the card 2a should not be Stabilization for + 6 V
powered unless the power transistor is hooked up. The secondary voltage of 50 V from transformer I is fused
The correct hook-up of these wires are from top down: on card 4a and also will be rectified here.
Blue (bu) No. 1 The input voltage of 6 V is being delivered by transformer
Grey (94 No. 2 I I. (As it is done for the 5 V supply on card 2a.I
Green (gn) No. 3 The above voltage is needed for the read-out display. A
The same markings can be found on the card itself. trim potentiometer is used to adjust the brightness of the
In addition, the connection plug itself is color marked display and it is recommended not to go over approxima-
accordingly. The output voltage can be checked on Test tely 5.5 V
Jack 2AGl. The voltage regulator is mounted on the heat sink. The lat-
In order to compensate for the voltage loss toward the ter is located on the right guiding post of the card. The 4
upper control panel, it is essential to set the voltage with connection wires are plugged in at the front of the card.
the aid of the Multi-Trim Potentiometer on the outside of The connection sequence is as follows:
the card, to 5.30 V - 5.40 V. Violett (vlt) No. 4
As the next step check the voltage directly on the card N- Green (gn) No. 3
MAV and make any correction with the potentiometer so Grey (!A No. 2
that a voltage of 5.10 V - 5.15 V is present on the card Blue (bu) No. 1
N-MAV itself. The same marking letters are also on the card itself.
It is of utmost importance to have all cards inserted during The presence of the voltage is visible by a light emitting
this voltage check and adjusting procedure, as otherwise diode.
wrong voltage conditions may be present. Fuses Ampere For Voltage
The given voltage on the card N-MAV (under any circum- 4el 4A for + 6 V =
stances) should not be above the maximum stated range, 4e2 2.5 A for 42 V =
even if it is only for a very short period of time. 4e3 4A for 5OVN
Any higher voltage will, most likely, damage the integrated
circuitry with its delicate components.
A red light diode on card 2a is visible if voltage on the 3.1 .I8 Control Board D
card is present but by no means indicates the correct vol- 3.1.18.1 Base Plate
tage itself. This voltage line is fused with 4A (fuse 2al). The control board D is mounted on the left of the lower
In addition to the above, this card also provides power for panel box adjacent to the power board P and is connected
the reset signal for card N-CPU. This signal interrupts the to the P board with cable PI 1 - D55. The base plate of the
function of the computer if the input voltage to card 2a D-Board is used for the plug-in of 6 cards.
drops under the prearranged minimum voltage and pre- The elctrical connection between base and cards is made
vents, therefore, any wrong miscalculation or function of through pin and mating prong terminal strips.
the computer. The cut-off point of the minimum voltage The plug-in cards are numerically marked from the left to
is preset at the factory and should not be altered. right. Since the cards la - 2a - 3a - 4a are located on th P-
Board, the next card on the D-Board will begin with 5.
3.1.17.3 Card 3a Rectifying and stabilization for+24 and -6V 3.1.18.2 Plug-In Card 5
The + 24 V DC and - 6 V DC are produced from the se- This card is needed for special operation features and pre-
condary output of 32 V and 9 V fom the control trans- sently not being used.
former I.
The stabilization of + 24 V is arranged through a power re- 3.1.18.3 Plug-In Card 6 Pixomat (optional Equipment)
gulator. This card contains all components necessary for the con-
The - 6 V DC are produced by an integrated linear recti- trol of the gripper margin motors and lay correction. The
f ier system. command input is received from the respective keys on
A test jack 3a Gl is provided to check the - 6 V and on the key-board. These signals are visible on the then lit up
test jack 3a G2 the + 24 V can be checked. Fixomat keys. The card 6 on the EMC machines is the sa-
Two (2) light diodes are provided to show the presence of me as being used on the CE models and, therefore, inter-
both voltages (red = - 6 V, yellow = + 24 V). changeable.
3.1.18.4- 3.1.19
3.1.18.4 Plug-in Card 7SB: 1. Cut Release By Hand Or Automatic Knife:

Safety bolt and blocking lift and retractable side gauge. Any malfunction within thisoperational stagewill block
Since in most countries, a mechanical stop within the knife the knife cycle. Also the clamp will not receive its hy-
motion is mandatory, all POLARs are so equipped.The Card draulic pressure.
7SB in its function, pulls the safety bolt out of its blocking 2. Knife Upstroke Movement After Cut:
position as soon as the knife cycle is started and brings the At this stage half of the emitter lamps will be turned off.
safety bolt back after completion of the knife cycle to If the light barrier does not react accordingty, the next
arrest any second downward motion of the knife. cutting cycle is blocked.
The other function of the card 7SB is the blocking of any The normal card 9 is designed for the connection to 3
hydraulic lift motion as well as any movement of the re- photo element pairs. For countries with other electrical
tractable side gauge during the duration of a cut cycle. code regulations, a special card 9 is available on which 5
The card 7SB is the same on the EMC machine as on the photo element pairs can b connected. This card is marked
CE models. ,9 LSE’. On the EMC machines card 9 has the ID number
015296 and 9 LSE has number 015297. These cards are
3.1.18.5 Plug-In Card 8: Cutting Circuit also usable on the CE models. Card 9 or 9 LSE with a
With the card 8, all conditions will ba checked under which lower ID number should not be used on the EMC models
a knife cycle is possible, i. e. cut button depressed simul- for reasons of voltage conditions.
taneously or automatic knife device turned on, light barrier
beam not interrupted, light barrier pre-checked positive, 3.1.19 RELAY BOARD C
back gauge at stop, cut circuit free by computer. If all The relay board C is located at the panel mounted to the
these conditions are complete, then the hydraulic solenoid rear table support bridge. The control relays for the table
on the hydraulic control block is energized and clamping motor are mounted on the C-Board.
as well as cutting is initiated. Contactor Cl2 is used to connect the table motor for for-
The card 8 also contains the electrical circuit for the non- ward rotation. Contactor Cl5 is used to reverse this rota-
repeat device which makes certain that knife and clamp tion. One other contactor C 11 is timed to both contactors
remain in the upper stop position regardless of the duration Cl2 and Cl 5 and on the opener contacts of Cl 1 the fast
on depressing the cut buttons. The result is that a second motor windings of the table motor are connected to it. If
knife cycle is only possible after release of both cut but- contactor Cl 1 is not energized, then forward and reverse
tons and a simultaneous pressing of both cut buttons again. is done in fast speed. On the other hand, if contactor C 11
Simultaneous in this respect means that both cut buttons is energized, then by contact through the closer-s, the win-
are depressed within 0,5 seconds as otherwise thecut cycle ding for slow speed is switched into the circuit. If at this
is blocked. The ,time limitation’ of 0,5 seconds is monito- operational stage the contactors C 12 or C 15 are energized,
red by a control device on card 8. The card 8 on the EMC then the backgauge will move in slow forward or reverse.
machines is the same as used with the CE models. Parallel to the connections for the backgauge motor win-
Since on the D-Bases of some older CE models the pre-con- dings one each screen condenser unit is hooked up and
dition for the function of time limitation does not exist. mounted to the C base plate. This screen condenser unit
Therefore, card 8 has a toggle switch allowing to bypass consists of 3 condensers and 3 resistors so arranged that
the time limitation device in this instance. With this feature, any interference from the on-off condition of the motor
the same card 8 can be used on older and newer models. or reversing the rotation will ba reduced oreliminated.The
backgauge motor itself can be protected against burn out
3.1.18.6 Plug-In Card 8c: Conical Valve Control Circuit through an overload switch.
The card 8c is required if the machine is equipped with The switching circuit for contactors Cl 1, C12, C15, is part
the new type hydraulic on which the clamp function is of the brake control card 22 which also is mounted to the
controlled by a conical valve in conjunction with the knife C-Board.
cycle. With the card 8c, all conditions are checked for pro- The 3 phase power for the backgauge motor is coming di-
per function of clamp movement. Accordingly, the coni- recly from the HP board by means of a male-female plug
cal valve solenoid is being switched on and off. connector. In addition, an AC voltage of 180 to 240 V
(depending on the main power voltage) is fed in the Relays
3.1.18.7 Plug-in Card 9: Light Barrier Amplifier Board C unit, to be used for the additional brake solenoid
The card 9 receives voltages from al I photo elements which (17a) of the backgauge motor.
have been subjected to proper light emitting focus. Within The brake solenoid (17a) is energized during the manual
the card 9 these small voltages are amplified to usable digi- operation forward or reverse by the respective contacts on
tal signals. Only if all photo elements are properly illumi- contactor Cl2 or C15. During the automatic operation,
nated is the output relay in a position to close the circuit this brake solenoid is permanently energized through the
for start cut’. relay d122 which is part of the card 22.
Since the light barrier is an important link within the safety The motor brake, therefore, is not action during the auto-
system on the machine, it is so arranged that on each cutt- matic operation.
ing cycle this light barrier circuitry is automatically moni- If the machine is equipped with an air blower for the air
tored 2 times for proper operational function in each stage. table, then the overload switch for the blower motor is
3.1.19-3.1.20
mounted to the C-Board. The overload switch isfactory set Keyboard Card N-T II ,Recording and Erasing’ with sig-
to the normal current draw of the motor. In case of an nal display
overload to the motor, this protection device will discon- Keyboard Card N-T I I I ,Automat’ with signal display
nect the motor from the power supply line. Keyboard Card N-T IV ,Numerical Keyboard’
The voltage supply line to the blower motor is a separate Potentiometer Card AV-POT with signal display
cable line from the HP board to the C-Board connected to Measurement Display I + II: N-MAZ I + II
both boards by a male-female plug. Backgauge Position Display - Backgauge Stop Display
If the machine is equipped with the Fixomat device, one I + Ii: N-ISA I + II
addional contactor Cl is mounted to the C-Board for the If machine is equipped with Fixomat, additional cards are
purpose of switching the 3d motor for the various rakes located to the left side on the front plate.
position on the backgauge. Keyboard Card N-FIX Key + LED ,Fixomat with Signal
The contactor Cl is electrically controlled from the card 6 Display’
(Fixomat) on the D-Board. Display Card N-Fix A ,Fixomat’
The relay board C is electrically connected to the power Also on the front plate, located and accessible for plug-in
board P and the board D by a number of plug connectors. from the front, is the interchangeable memory bank.
Also plug connectors are used (on the Relay Board C) to All Keyboard Cards, as well as the Potentiometer Card,
make the electrical connection to the table motor, table with their signal displays, are of a plug-in type design and
brake, air blower motor, air solenoid and motor brake so- can be removed toward the front after loosening the side
lenoid (17a). sheet metal screws.
The electronic control system is placed on 7 plug-in cards,
3.1.19.1 Plug-In Card 22: Brake Control Card with the card dimension of 233 m/m x 160 m/m, as follows:
Digital signal impulses, coming from the interface card out N-Cl Cassette Interface (in between link to memory
of the upper control panel box, are received by card 22 bank and computer)
and converted to a usable function of the backgauge. N-l Interface card (in between link to external switch
The ,on’signals of d12 or d15 are used to switch in contac- elements and computer)
tor Cl 2 for forward or Cl 5 for reverse. N-MAV Measurement Amplifier and Gripper Margin Com-
With the additional ,on’ signal of dll, the contactor Cl 1 pensation
is switched also into the circuit and the table motor now N-KB Keyboard (Numerical Electronical System)
will run in slow speed. N-CPU Central Processing Unit or Computer
The relays d12 and d15 are also used to switch off the N-Z Counter
table brake coil during the manual operation sequence for N-MS Automatic Knife and Special Equipment
forward or reverse. In the automatic operational stage, the If machine is equipped with Fixomat, the respective card
brake control is done through signals from the interface card N-F Fixomat is located on the left side of the upper con-
to relay d70 whereby the brake coil is controlled through trol panel box.
relays d12 and d15 in conjunction with the d122 relay. All above cards are connected to the base by multiple plug
In order to achieve a quick and uniform brake action, a connectors (64 pins). The connectionsof thedigitaldisplay
voltage pulse is used at this stage produced by the discharge and input stages to the respective cards are made by flat
of a condenser. The condenser is charged with approxima- type wire connectors which are situated on the upper card
tely 120 V. edge. To assure the correct plug-in direction, all pin termi-
The discharge of the condenser is done automatically over nal strips have a marking point either on the soldering side
a thyristor device as soon as the brake coil is switched in. of the card or the side with the electrical components. The
A holding voltage of approximately 20 V is applied to the flat type wire connector has to be plugged in with the
brake. marking wire facing the marking point on the card.
If the backgauge is moved by the hand fine adjustment, The base is divided in 3 sections to hold the individual
the brake is switched off by the limit switch b18b. cards in groups. The printed circuits of the cards are con-
nected to each other by 6 VG terminal strips and a 64 pin
flat type wire package. To prevent mistakes in inserting the
3.1.20 UPPER CONTROL PANEL individual cards, special plastic index stops are provided on
The front cover of the control panel can be removed after the base to mate with the individual card. They are always
the 6 lentil countersunk screws and the turnable knobs have located at the terminal plug I on each card. The exceptions
been loosened. After the holding screws (one on each side) are Card N-Cl and N-KB. Here it was impossible to provide
have been loosened, the complete upper control board can the plastic index stop for reason of available space.
be pulled out towards the front. Even in this pulled out Furthermore on all cards the identification marking in ab-
condition, the machine functions are not interrupped. breviation letters are to be found on the Release Lever (e.
Located within the front plate of the control board are g. N-CPU) as well as on the base plate itself.
the following cards: Three Test Jacks are- provided on the left section of the
Keyboard Card N-T I Program Selection and Memory base plate. (Banana type jacks 4 mm 0 accessible from
Space Selector’ the bottom)
3.1.20 - 3.1.20.6
Blue = ov ATTENTION: In case of a mechanical failure on one

Red approx. = + 5 V (Power Supply For The It’s) of the push buttons (button does not
Yellow approx. = + 24 V (Relays And Switches) pop out again) all other operational
Another Test Jack is provided on the center section of the functions are blocked electronically.
base
Green approx. = 5.5 V (Seven Digital Display)
The exact Voltage values are to be found within the ,ln- 3.1.20.3 Push Button Plate ,Automat’ N-TIII
structions For Voltage Adjustments’. This group consists of the push button base and the base
All Test Jacks are accessible from the bottom when the for the 3 light diodes.
Control Board Unit is pulled out. The following push buttons are mounted on the plate:
On machines manufactured in 1979 2 additional Test Jacks Automat Backgauge ,Off ‘
(2 mm 0) for checking voltage supply to the 6~‘s are pro- Automat Backgauge ,On’ Express
vided on the card N-MAV. (Consult the Instructions For Automat Backgauge ,On’ Slow
Voltage Adjustments). Automatic Knife ,Off’
The rear printed circuit holds also the 6 align switches for Automatic Knife Prepared
adjustment of the reference point as well as the plug con- The respective signal light diodes are switched on by the
nections for the input and output cables. corresponding push button ,Automat Backgauge On Ex-
Within some of the first manufactured upper control panels, press’, Automat Backgauge On Slow’and ,Automatic Kni-
the base unit is not divided in sections and no Test Jacks fe Prepared’.
are provided. Voltage checks etc., should be made in these The electrical connection to the card N-KB is done with a
instances on the large open wire lines. 14 pin flat wire strip connector.
It is also to advise that on these early bases no index stops The signals for the light diodes are received from card N-Cl
are provided for the proper card plug-in procedure and whereby a 10 pin flat wire strip connector is used for the
special caution is necessary to use the correct card for the electrical connection.
correct position. If necessary, the wiring diagram shouid Two cables, soldered to the push button plate, are making
be consulted for proper location of the individual card. the connection to the card ,Recording Storage and Erasing’.
On the plug in card N-MAV are placed two test receptacles
blue = ov
red = + 5,lO - 5,15 v 3.1.20.4 Push Button Plate ,Numerical Keyboard’ N-TIV
This important voltage secures the power supply for the The push button plate consists of 36 keys to program the
calculator. The adjustment takes place on plug in card 2. complete sequence and measurements within the individu-
See also ,Instruction For Voltage Regulation’. al stages of the cutting procedure. (The meaning of the in-
dividual keys are described in the Operation Manual.)
3.1.20.1 Push Button Plate ,Program Selection and Memo- The electrical connection to the card N-KB is done with a
ry Space Selector’N-TI 34 pin flat wire strip connector and the signalsforthe light
This push button plate holds the following push buttons: diodes are received from card N-Cl via a 26 pin flat wire
Program Selection Upward strip connector.
Program Selection Downward
Memory Space Selection Upward
Memory Space Seiection Downward 3.1.20.5 Group Potentiometer
The electrica connection with the card N-KB is done with This group consists of 3 potentiometers (10 K Ohm each)
a 20 pin flat wire strip connector. used for the gripper margin adjustment I and 66 and the
measurment correction. The respective light diodesarealso
3.1.20.2 Push Button Plate ,Recording Storage and part of this group.
Erasing’ N-TII The electrical connection to the card N-MAV is done with
The complete group consists of the push button base and a 20 pin flat wire strip connector.
the base plate for the light diode.
The following push buttons are mounted on the plate:
Available Cuts 3.1.20.6 Plug-In Unit N-MA2 6 and N-MA2 II (Measure-
Marking with Cut and Prepare for ment Display)
Erasing Multiple Program These two plug-in units are located on the front board and
Erasing Button are connected to each other directly by 11 (eleven) male
Memory input Button and female terminal strips (IO poles). The most forward
The indicator light is positioned above the push button unit (N-MAZ I) contains the 15 m/m high 6 digit measure-
,Marking with Cut’ ment display (backgauge position), the display for the
The electrical connection to card N-KB is done with a 10 backgauge direction (+ -), the 2 digit 8 m/m high display
pin flat wire strip connector. for the program number and the 3 digit display for the
The electrical connection to the push plate ,Automatic’ is memory counter. The latter display is also of 8 m/m height.
done with 2 fiat type plug connectors. The rearward unit holds the logic function elementsand its
3.1.20.6 - 3.1.20.10
connection is made with two 26 pin fiat wire strip connec- git ,Total Cut‘ display as well as the over count and minus
tors to the card N-KB and the number dispalay N-ISA I I. display.
The numerical display is arranged with 7 segment bars in All 7 segment bar displays are 8 m/m high and are of the
which the 7 light emmitting diodes are used to produce plug-in type.
numbers from 0 to 9. The unit N-ISA II holds the input stage logic decoder and
is electrically connected to the unit N-MAZ I I by a 26 pin
plug type flat wire strip connector.
The basic functions of the N-ISA units are the same as the
N-MAZ units. All necessary signals are received from the
N-MA2 II unit.
The transfer of display information from card N-KB to
the numerical display unit is done with the time multiplex 3.1.20.8 Plug-In Card N-Cl
system (see picture). With this system all display configu- This card divides the function of the CPU card and the in-
rations are lit up in very short intervals but since these re- terchangeable memory bank. All memory feed-in data and
peating intervals are of an extremely short time lag (appro- read-out signal impulses are produced here.
ximately 1000 x per second) the human eye with a certain In addition, this card holds the amplification for the light
indolence can only observe a constant light. Therefore, the diodes and the control lights for the push buttons. The
given information to the individual segments are visible on connection is made with the flat wire strip plug f and g.
all display configurations at the same time. The respective
area of the display is chosen by a separate ,Point of Dis- 3.1.20.9 Plug-In Card N-l
play’ control. Due to the synchronized changes of signals The interface card amplifies the output signals from the
for the light bars and point of display, the individual num- central processing unit card (CPU) in order for the relays
bers are lit up successively. (i. e. table motor) to be energized.
Since the counter, connected to the linear measuring scale, Besides the above, the input signals (i.e. limit switches) are
will give the output data only in digital pulses to the com- electronically aligned and coordinated to the voltage con-
puter and the computer itself also feeds out digital signals dition of the CPU card.
only, these signals now have to be transformed in such a A Relay (d88) is provided for the control of the air system.
way that they can be used for the 7 segment bar display. A number of light diodes are in the circuit to show the in-
Special Decoder chips are used to transform these digital put signals (yellow) and also to show the output signals,
signals into a useable analog form. produced by the CPU card, in Red Display. (See Control
The computer delivers 2 groups of signals (BCD Code) Diagrams.)
needed for the input stage on the segments via the card
N-KB, separated in the group for even display numbers 3.1.20.10 Plug-In Card N-MAV
(A0 - A2) and for uneven display numbers (BO - B3) Measurement Amplifier and Gripper Margin Adjustment
(see picture). These signals are given to one each decoder The card N-MAV contains the amplifier for the Linear Me-
and here the converting from the binary-coded decimal asuring Scale and the processing electronic for the Poten-
signals into the 7 segment signals takes place. tiometers of gripper margin device I and II, as well as the
The correct placing, which BCD code signal belongs to correction device for the strip size.
which point of display, is arranged by another decoder Measurement Amplifier
unit (place decoder) where the incoming 4 digit signal SO This amplifier amplifies the three sinus wave shapevoltages
- S3 is decoded and the respective O-Impulse is produced produced in scanning the Linear Measuring Scale. After
for the BCD 7 segment decoder. amplification, these signals are transformed to digital sig-
To prevent any incorrect display during the switch-over of nals (square wave pulses) so that they can be used within
the BCD code, it is electronically arranged that the O-lm- the counter for further processing (See plug-in card N-Z as
pulse is only given if the computer shows, via the BD sig- well as description of the Linear Measuring Scale).
nal, that the correct data has been received. (Monitored Gripper Margin Adjustment
by stage (M F) monof lop and stage gate.) The voltage from the 3 output taps of the Potentiometers
All 7 segment display bars are of 8 m/m height and moun- gripper margin I and II and the correction device is fed in-
ted on plug-in type sockets. to the Analog-Digital processor. This device now analyzed
the analog voltage values given by the 3 Potentiometer
3.1.20.7 Plug-In Unit N-ISA I and N-ISA II (Back Gauge positions and converts these impulses to a digital informa-
Stop Display) tion (8 Bit). The center position of the Potentiometer range
Both plug-in units are mounted on the front board to the is designated as value 0 (zero).
right of the display N-MAZ. The electrical connection is The computer receives a specific signal if the Potentiome-
made directly to each other with 11 (eleven) male and ter is moved out of Zero position and in this case, the re-
female terminal strips (IO poles). spective light diode will light up.
The most forward unit (N-ISA I) holds the-6 digit ,Back- The Analog-Digital processor constantly feeds-in the Po-
gauge Stop’ display, the 2 ,Cut Counter’ display, the 3 di- tentiometer position to a memory bank and with a read
3.1.20.6a
3.1.20.6a
Time - multiplex system
__---
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
3.1.20.6b
3.1.20.6b N-MA2
A
/ \
N- KB
3.1.20.7
3.1.20.7 N-ISA
3.1.20.10 - 3.1.20.13
pulse from the computer, the required data is retrieved However, if only occasionally one or the other measuring
and switched to the data link for further processing in the systems are used, then it will only be necessary to push
computer. the key ,Gripper Margin Adjustment I’ once before the re-
The signals for selection of the individual Potentiometer ference point is scanned.
and the memory bank are produced in the electronic con- Important: The slide switch has to be set also be-
trol system. The sequencer is responsible for the impulses fore the reference point scanning ta-
being fed into the Analog-Digital processor. kes place and not after as otherwise
Test Jacks the measurement display readout will
Beginning with manufacturing year 1979, these cards have not show any change. (Only after the
now 2 Test Jacks (Red, Blue) located on the upper por- machine is turned on again will the
tion of the cards and accessible thru respective cut outs on change go in effect.)
the Cover Panel. This function befalls in the meantime
These Test Points are used to check the exact adjustment only machines with EPROMs dated
of the supply voltage for the IC’s. (See Instructions For 6.7.1979
Voltage Adjustment)
3.1.20.12 Plug-In Card N-CPU
3.1.20.11 Plug-In Card N-KB The CPU card is the main central part of the complete
The keyboard card is used for the automatically distributi- processing unit. This card receives all input signals from
on of numerical datas, produced within the CPU card, to push buttons, limit switches, etc. ; converts them to logic
the individual displays. These datas are rechecked by the output impulses suitable for the control of the backgauge
computer and then transfered by the card within a speci- motor in standard-eltromat or eltrotact operation, as well
fic sequence to the respective display read out. (Flat wire as the cutting cycle release and the impulse signals for the
terminal strip plug a.) respective light bulbs and display area diodes. (Not the
In addition to this connection, there are the plug connec- fixomat light.)
tons b, c, d, e to the individual push button cards. The in- In addition, certain functions of the inter-changeable me-
dividual push impulses are recorded in the memory bank mory bank and control of the optional features are prepa-
as they are given and then stored in this sequence to be red and released from this CPU card.
available for the CPU card. The transfer to the processing The electronic sequence of input and output as well as the
card is done via the plug I at constant repeated times. control itself is governed by the stored data within the
Also controlled from this N-KB Card is the acoustical sig- memory bank Chips 1 - 4. (See Chart.)
nal effect located on the position display. Specific operational positions of the machine are registered
On the right side of the card are two contact pins. and displayed with light diodes.
If both contact pins are connected by a wire jumper the Errors within the operational procedures are signaled thru
brake afterrun distance is visible on the display after the the Chips 2 - 7.
reference point has been scanned. All in and output signals are transmitted via Plug I I. Other
The Retrieve Push Button is to be pushed in and now the datas from measurement amplifier, counter device, memo-
actual distance of the brake afterrun will be shown in the ry interface card and keyboard card are transmitted via
backgauge Stop Display. Plug I.
In the center of the upper part of the card are 2 slide swit- The switch on this card should not be used and operated.
ches positioned. Only For Specific Testing Procedure At The Factory
The right switch is used to turn off the correction devise.
The purpose of the correction device is to compensate va- 3.1.20.13 Plug-In Card N-Z
riations within the last digits on the measurement display The counter card is counting all impulses from the mea-
if these variations fall below rfr. 81’100 mm. surement amplifier according to their value (Positive - Ne-
With this feature a clearer and easier to read display is gative) and has therefore all the time the exact backgauge
accomplished. (This switch can be operated even with the position available.
machine in full operation.) In scanning the reference point, by the backgauge move-
The left switch is used to choose the display readout in ment, these counters receive the reference measurement,
mm or inch. This feature will mostly be used if on theaver- which is adjustable to the individual table size via the cor-
age, only one measuring system (inch or mm) is needed rection device switches, as a specific impulse signal.
for the machine operation. For Service purpose, special check points are provided on
which an auxiliary display system can be connected too, so
inch without correction
that the individual uncorrected counter positions can be
seen.
-i I I I Jug
I The counter card also holds a register device in which the
destination measurement of each backgauge cycle has been
orrection Brake afterrun’ fed in from the CPU card.
If both stored values, the counter position to the destina-
tion measurement register, are in agreement then the brake
Position of slide switches for mm/Inch and correction action will be released from the counter card.
L--- J
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Zero Indicator
- -
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Read
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Signois Data
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Link
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bm putcr
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Computer aositionj
3.1.20.14- 3.1.20.15
3.1.20.14 Plug-In Card N-MS (Automatic Knife And The power output of the Reed Relay is approx. max. 10 W
Optional Features) by max 500 mA and max. 100 V (Ohm Load). Each con-
tact (closer) will be closed for approx. 500 ms.
This card holds the electronic safety circuit for the auto- The potential free terminals with the output side are con-
matic knife feature as well as the control system for all nected on Plug STK 31 on the control panel box and wired
the special operational features. to Plug No. 18, which is placed an a cable raceway at the
If the backgauge is switched to automatic and the push rear, behind the lower control box. The individual output
button ,Automatic Knife Prepared’ ( (!/ ) selected, then terminals have the connection on Plug 18 as follows:
the control display ,Automatic Knife On’ will now light 18.7 The control signals for the Fixomat
Fixomat
up with a bright illumination. (The control display in the 18.10 are already fed into card N-F at the
,Before Stage’was only dim.) upper control box. The additional wi-
In pressing the 2 cut buttons the automatic knife circuit is 18.1 ring to Plug 18 means only a parallel
Fixomat
switched into such a pattern that only after a backgauge 18.4 connection. If the machine does not
stop and after the card N-CPU has given the free signal, a have the Fixomat feature, then these
knife cycle can take place. 18.3 sianals can be used for other control
Fixomat ”
The control light ,Automatic Knife On’ is now switched to 18.8 systems. The control signals are alrea-
a flashing condition. dy available before the backgauge
The automatic knife will stop if: movement to the respective backgauge
The L.S. light barrier beam is broken during the stop position is started.
cutting cycle, 18.5 The control signals on these terminals
, 8 6 Transomat
The L.S. monitoring system is detecting a malfunc- are freely avalaible at the time when
tion in the L.S. circuit, the backgauge has reached the respec-
The backgauge reverse movement takes place, 18.11 Retractable tive measurement stop position,
The backgauge has reached the front limitation stop, 18.12 Side Gauge
The push button ,Automatic KnifeOff’( q ) ispushed,
The push button ,Backgauge Automatic Off’ (0) is 3.1.20.15 Plug-In Card N-F Fixomat
pushed, This card N-F, in conjunction with the card 6 in the D-Base
The control light for ,Automatic Knife’ is burned out, and the push button plate as well as the display card, con-
The backgauge has not reached the specific measure- trols the electronic system for the Fixomat motors.
ment position for any reason. The voltage for the 2 directional systems of the angle cor-
rection device is changed within the Analog-Digital con-
3 light diodes for function control (warning of mdfUnC- verter and fed to the 2 seven segment display read out.
tions), are located on the upper card edge. (The 7 segment bars are only illuminated when the respec-
The left diode (yellow) marked with K8-20, becomes illu- tive relay becomes involved thru the push button ,Angle
minated at the start of the cutting cycle and stays on during Correction ,Left’ or Right”.) The reverse position and
the duration of the cycle. using the push button ,bo’ will turn off the display signal.
The center light diode (yellow) marked with d37 is hooked The control devices for .Angle Correction’ and ,Gripper
up parallel to the control pilot light of the L.S. and stays Margin’ are producing the signals for energizing Relays dl
lit up constantly except for a brief interruption during the - d2 respectively d3 - d4 and Relay d5 - d6 resp. d7,
monitoring stage of the L S. circuit during the knife up (on card 6).
stroke. The display for position of theGripper Margin iscontrolled
The light diode on the right (Red) marked with d73 is by the limit switches bol , bal, bbl resp. bcl.
hooked up parallel to coil of relay d73. Furthermore, it is possible to control the Gripper Margin
If push button ,Backgauge Automatic On’ (ExpreR or pairs (not the angle correction) via the potential-free ter-
Slow) and push button ,Automatic Knife prepared’ are minals of the optional features (from card N-MS) with
pushed in, this red light diode will go on at the beginning specific computer orders. In this case, the output stage
of the cutting cycle and will go off when the knife is start- signal -10 is automatically used in the computer to reduce
ing the upstroke. (At the time when the gear limit swit- the specific measurement by 10 mm. The processor also
ches are taking over.) This ,On’ and ,Off’ condition is in brings back the Gripper Margin device to the initial Zero
effect at each cutting cycle during the ,Automatic Knife’ position when the push button bo is engaged. The Proces-
operation. sor also receives a signal for the display indication that the
The individual selection of special operational functions is card N-F (as optional feature) is available. (See Display ,P’)
given by 5 identical switching steps. These steps are selec- The Angle Correction and the Gripper Margin adjustment
ted by the operator according to the program needs and in are electronically blocked to each other. This means that
no way will it be necessary to follow a certain sequence the Gripper Margin adjustment cannot be moved out of
for employing the individual step. position if the Angle Correction has been adjusted or vise-
Each switching step consists of a monoflop, a driver stage versa.
and a reed relay. With this arrangement we have 5 poten- If the Gripper Margin adjustment is moved to an ,Out’ po-
tial free output terminals (closers) available. sition and the attempt is made to use the Angle Correction,
-1..--
Display Fixomot S
br
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Control from Computer
Aften tion Analog-Digital

Processor
8V.w Reverse sigml

d317 from computer
Adjusl?nent ftr + 5v
angh9 corrntion
plug inchart r -- - Signal far computer
No6 ,
c?J d :/ 651 dj that Fixomat is present
d31b
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Direction unit
Fixomat S
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P
3.1.20.15 - 3.1.30
then the light display indicator for Angle Correction will able Memory Bank Unit has been taken out of the machine.
light up, but no correction will take place. The Memory Bank Unit receives its voltage from the ma-
For alignment purpose on the Angle Correction Display, chine-electronic when the machine is turned on and at the
2 Potentiometers are provided, located on the upper part same time the Buffer Battery is being recharged.
of the card N-F, of which the Right Potentiometer responds ,RAM’ = Random Access Memory = Write - Read Storage
to the Right Angle Correction. The other Potentiometer is Unit
factory set and should not be tampered with. The infeed, reading and erasing of data is being done via
The power supply of + 5 V and - 5 V for the Analog-Digi- the Cassette Interface Card N-Cl controlled by electronic
tal processor and the display for Angle Correction has to instructions from the computer.
be separated from the other power lines. The Inter-Changeable Memory-Bank Unit can be removed
The voltage for the Analog-Digital processor is taken from from the machine any time or at any function cycle posi-
the Control Transformer I (0 V., 8 V., 16 V.) and fused on tion of the machine without loss or change of the stored
the card N-F with 2 fuses 0.5 A. data.
This voltage now is being rectified to DC and stabilized by If a memory unit should be kept outside of the machine
2 integrated voltage stabilizers. longer than 1 month, this must be done only in connecting
The TransformerTAP 8 V is hereby the ,O’ position where- with the maintenance charging unit switched on.
as the 0 V Tap respectively the 16 V Tap is used for the
rectification of the positive or negative voltage. 3.1.30 Linear Measuring System
The connection of card N-F to the card 6, the Control The Linear Measuring Scale is producing a number of elec-
Transformer I to the backgauge (Direction Control System tronic signals equal the distance the backgauge has moved.
and Fixomat Motors) is done with a 26 pin multiple plug. These signals are now amplified within the electronic in
The connection of card N-F to the 2 Digit Display is done the upper control box, separated - counted and transferred
by using a 16 prong flat wire strip connector. (Plug A) to the read OUT Display as the backgauge stop position.
A IO prong connector B and the 14 prong connector C are Inside the Linear Measuring System, which is totally en-
the connection to the Keyboard card ,Fixomat’. closed, is a very precise Glass Scale on which fine scanning
Please Observe: The 7 segment bar display units (8 lines (0.04 mm a part) are marked on. In addition to this
mm high) are not interchangeable full length Rasterfield, there is a small scanning line area
with the display units of MAZ and in approx. the center of the glass scale (on the bottom
ISA despite the same 8 mm heights. side) as the point for the reference mark.
The electrical control for the adjustment of the gripper During the backgauge movement a Photoelectric Scanner
margin device by the computer is done via the Relays for Head is passing over the fine scanner lines and as a result
optional features on the card N-MS. certain impulse signals are produced (See Picture a). The
produced signal from the Photoelements is a sinus wave
3.1.20.16 Inter-Changeable Memory Bank N-DS type. The Glass Scale is being scanned by 3 pair Photo-
The Memory Bank Unit is inserted into the upper control elements (output stage O”, 90° and reference point) where-
panel. With this the connection to the rear base is made by Light emitter
a 37 Prong Plug Connector.
The correct position of the Memory Bank Unit is reached
when its front cover plate is flush with the control panel
front surface.
The Inter-Changeable Memory Bank as a unit consists of 3 \ Optic
individual storage cells which, together with a Buffer Bat-
/
L \-
-%...)J
tery, are housed in a plastic container.
The Storage cells are ,RAM’ Chips (Random Access Me-
mory) to which specific datas or characters of language is j Moveable scanner haad
fed into, using the Bit Type System. I

i
With the characters of language, it is now possible for the
c
computer to retrieve specific data or to erase certain indi- I I \
‘iStationary glass scale
vidual data combinations as well as to erase the complete
memory bank at once.
Altogether, this Inter-Changeable Memory Bank has a sto-
rage capacity of 512 Bit Words. This means that it is pos-
sible to store 6 digit measurements and up to 11 optional
functions in each Bit Unit. Out of the 512 Bit Words,
arrangements for 98 programs can be made.
The RAM Chips are only capable to sustain the memory
data if they are held on a specific voltage. A Buffer Battery
\, Photo element
is provided to prevent any loss even if the machine is
turned off for a longer period of time or if the Inter-Change- Picture a: Prinziple drawing optical - electronic scanning
3.1.30 - 3.1.30.1
by each Photoelement, within the pair, is connected With the adjustment of the reference point, the true di-
against each other (Anti-Parallel). As the light emitter for stance between back of knife cutting line and front surfa-
the system a mini glow bulb of 5 V 120 mA is used, which ce of the backgauge rakes are brought in alignment to the
has a predicted medium lifetime of approx. 100000 hours. backgauge position display read-out.
A faint light on the scanner head (looking from below) in- The reference point on the EMC machines is already estab-
dicates a lit up glow bulb. lished at the factory and it only will be necessary during
Purpose Of The Reference Point Is As Follows: the installation to recheck this point and readjust if needed,
If the machine is turned off, the backgauge position infor- Before the upper control box is mounted, a rough align-
mation is lost for the computer and no measurement dis- ment of the reference point is done by setting the various
play will be visible when the machine is turned on again. align switches, which are located on the rear wiring base,
In moving the backgauge thru the reference point, a signal to a measurement data approximately l/2 of the full back-
from scanning this reference point will go to theelectronic gauge movement distance.
control system, giving the instruction to the computer On a POLAR 155 EMC this data would be 775 cm
that this measurement has to be accepted. (Providing that On a POLAR 115 EMC this data would be 575 cm
the established distance, pre-determined with the align If the reference point was already set and only a recheck
switches, between backgauge rake and knife back side has or small correction is necessary, then the before mentioned
been stored in the Memory Bank.) (See Chapter adjustment rough calibration procedure can be emitted.
reference point.) Procedure For Fine Adjustment:
The additional impulse signals from the Linear Measuring A small paper ream af approximately 3 cm height is being
Scale are now added or subtracted to this established data cut on one side. Bring backgauge to a full measurement of
and the correct measurement should be visible on the Read IO cm, using the backgauge position display read-out, turn
Out Display. The signals Oo and 900 are used to determine the paper ream 180° and after careful positioning against
the direction. Since the individual photoelement pairs are the backgauge rake, make the second cut.
mounted in an offset pattern to each other, the output Check paper now with a pocket caliper. Let’s assume, for
signals are therefore phase shifted by 90°. (See Picture b.) example, the measurement is 8,385, which means in this
Depending on the backgauge movement, Forward or Re- case that the paper is shorter than the digital read-out
verse, is the O” signal received before or after the 90° sig- shows.
nal. This specific relation is then the base to establish the Now we have to figure out the actual difference between
signal Forward or Reverse and at the same time the impul- the display measurement and the cut size.
se counter will count Up or Down. 10,000 cm
The Read-Out Measurement Display will show ,-’ for the - 8,385 cm
Forward movement and ,+‘for the Reverse movement.
In order to increase the scanning accuracy on the Scanning 1,615cm
Line Spacing from 4/100 mm to I/100 mm, the impulses The distance of 1.615 will now be subtracted from the sett-
are electronically multiplied 4 times. ing on the align switches. (If the actual cut would have
To accomplish this, the following is done: been larger then the difference should have been added.)
The received impulse signals are not taken by their full 77,500 (Setting on Align Switches)
wave length but rather only the ascending portion and - 1,615
declining portion of the signal (O” - 90°) is utilized.
The result is a far higher number of impulses available. 75,885 /New Setting Data For Align Switches)
ATTENTION : During Service Work on the Linear Mea- The align switches are now corrected according to the new
suring Systen DO NOT connect or dis- final data.
connect any plug when unit is still un- After the correction has been done, backgauge has to be
der power. moved over the reference point in order that the corrected
measurement can be effective.
3.1.30.1 Establishing of Reference Measurement Point It is advisable to test cut the new position by cutting three
Before any attempt is made to establish or adjust the refe- (3) equal sizes as described in the Service Manual.
rence point, it is necessary to have the over-undercut and For the correction procedure, it is mandatory to move the
parallel cut very exactly adjusted. backgauge only in standard position.
m dm cm mm I/ 70mm l/lOOmm
3.1.30b
3.1.30b Impulses of linear measuring scale
Current for signal “90°”
Reference point signal
Signal after imputsforming "0“'
I Signal after impulsforming” 90°”
Reference signal after impulsforming
1nnn Counted impulses multiplied .4x

3.1.3oc
3.1.3012 Connections on linear measuring scale
light emitter ph o toe/c mcnts

5V; 12OmA
--@-
w= svt 7O~lo Signal O0 Signal 90° Reference signal Shielding
I cu lEDmA
Pin position and wnnection ;(c Inside shield on pin 9

Outside shield on plughousing
Color coding 1: green

2: yellow
3: brown
L: white
5: blue
6: red
7: gfey
8: pink
9: shielding
Attention: Do not connect or disconnect any plug underpower

3.1.30.2
3.1.30.2 Establishing Of Backgauge Position (Measurement

Display)
For the ascertainment of the backgauge position, the fol-
lowing Group Units are involved:
Linear Measurement Scale . . . (Generates the Impulses)
Card N-MAV . , . . . . . . . . (Amplifies the Impulses and
transform them to Square Type Signals)
Card N-Z . . . . . , . . . . . . . (Is Counting the Impulses)
Card N-CPU . . . . . . . . . . (Processes the Impulse Data)
Card N-KB . . . . . . . . . . . . (Prepares the Impulses for
Display Read-Out)
Card N-MAZ . . , . . . . . . . . . . (Measurement Display)
The signals from the Linear Measuring Scale during the
backgauge movement are transmitted via a multiple shield-
ed special cable to the Card N-MAV. (See picture a + b.)
In this card the relative weak sinus-shaped signals are am-
plified and transformed to Square Type Impulses.
These impulses are now counted in the N-Z Card. This in-
formation is then forwarded via the Data Link DO - D7
Attention
to the Card N-CPU, where the processing of this informa-
Plugs and couplrngs Ll- LZ- L3 should not have any connections
tion takes place. (Measurement Correction etc.) to ground of machine
Again, the Data Link is used to transmit the information

to the Card N-KB. In this card the final processing of in-
formation takes place so that in the next stage the Mea-
surement Display N-MAZ can bring the Direct Read-Out
for the backgauge position.
Lineur measurement scale
Data link
3.2 - 3.2.10.2
3.2 Operational ~e~ription If a small false clamp plate is inserted and/or the Fixomat
layer rakes are protruded then the backgauge forward
3.2.10 POLAR 115 - 155 EMC movement is stopped before the limit switch b9 is reached.
3.2.10.1 Backgauge Forward on Standard Operation The ,and’ condition for control of backgauge forward is
Pulling the handwheel of the hand fine adjustment actuates also not in existance if the handwheel of the fine adjust-
the micro-switch blO(b). The working contact closes and ment has been released and micro-switch blO(b) is not en-
+ 24 V is fed to the input stage I I 12a of the interface card gaged anymore.
N-l in the upper control panel. This signal is now transfor- The yellow light El0 and the red light Al2 are out. Relay
med within the respective koppler and acknowledged by d12 and contactor Cl2 drop off. Backgauge motor is tur-
the yellow bulb El0 which becomes illuminated. ned off.
The transformed signal is fed to the computer via ll.23a. With contactor Cl2 energized, its working contact swit-
After a certain coordination and comparison toward back- ching the brake solenoid m17a of backgauge motor to on
gauge forward movement, an impulse signal is released via and the backgauge motor can now freely turn.
ll.28a to the interface card N-l. This control signal again is With the de- energizing of contactor C12, the brake sole-
checked in the card N-l with the contact position of limit noid m17a will also be de-energized and the motor is bra-
switch b8, b9 as well as b217, if machine is equipped with ked by spring tension.
Fixomat and/or the small false clamp plate. The brake solenoid is connected to 220 V AC.
If these limit switches are not triggered and the closer con-
tacts in the making position, a voltage of + 24 V is on the
input stage I I .I 3a of the interface card N-l. The respective 3.2.10.2 Backgauge Reverse in Standard Operation
koppler transforms this signal and the bulb E8will light up. In pressing the Push Button b14 on the hand fine adjust-
The impulse signal forward from the computer in connec- ment wheel, the ground potential to the + 42 V supply
tion with the position signal ‘forward limit switchesclosed’ line is made via the brass ring, carbon brush and input stage
being put to the ,and gate’ on which 24 V from the output ll.14a on the interface card N-l. This potential is being
signal ,backgauge movement on’ is present, will be fed to transformed within the respective koppler and acknowle-
the interface card terminal ll.7a. The red light (bulb Al2) ged by the yellow light E14.
will acknowledge this transaction. The transformed signal coming now from the output stage
The + 24 V signal on output stage ll.Qa of the interface 11.24~ of Card N-l is fed into the computer. After checking
card N-l is now given via connection 2 on plug-in card 22 all the necessary conditions for a backgauge reverse move-
(C-Board) to the coil of relay dl2, the test receptacle 22134 ment, electronically within the computer, a control signal
shows ,I’ signal. Relay d12 will become energized and its is given via I l.28a to the Card N-l. This signal now will be
closer contact are now switching-in contactor C12. coordinated to the contact position of Limit Switch b13
The contactor Cl2 is switching the backgauge motor to and arranged to a ,AND’ condition.
forward ,on’. If the backgauge is moved forward to the If Limit Switch b13 is not triggered and the closer con-
table limit switches area, the first limit switch to be trig- tacts are still closed, the + 24 V are present on input stage
gered is limit switch b8. The normally closed contacts 11.13~ of Card N-l. This signal too is being transformed in
open up. the respective koppler and acknowledged by the yellow
If the normal size false clamp plate is inserted in the clamp light E13.
and the limit switch b6 being triggered, its normally clo- The control signal REVERSE’ coming from the computer
sed contact open up and the + 24 V signal on input stage and joined with the signal from ,Limit Switch Reverse con-
11.13~ of the interface card N-l is being disconnected. The tact closed’ together form the + 24 V output signal ,Back-
yellow light (bulb E8) will go off. Since the ,and’ condi- gauge Reverse‘ on 11.9~ of Card N-l. The red light A15 will
tion for the output signal ,forward on’ within the circuit is light up.
not in existance anymore, the red light (bulb A12) will be Via connection 1 on Card 22a voltage of + 24 V is put to
Off. the coil of Relay d15. The Test Jack 22R3 shows signal ,I:
The output stage ll.7a of interface card N-l will receive Relay d15 pulls in and with the respective working contact
now the ,0’ potential and relay d12 becomes de-energized via contact on Cl5 the backgauge motor is started in re-
which, in turn, de-energizes contactor Cl2 and the back- verse.
gauge motor is turned off. The test receptacle 22R4 shows If the back gauge is reaching the end Limit Switch b13
,0’ signal. and opens the closer contacts, the + 24 V signal on input
If no false clamp plate is inserted and, therefore, the closer 11.13~ of Card N-l is interrupted and the yellow light El3
contact of limit switch b6 remains closed, the forward will go out. With this condition, the ,AND’ arrangement
movement of the backgauge will trigger now limit switch for the output signal on 11.9~ of Card N-l is cancelled. The
b8 but the + 24 V signal on ll.13a of card N-l is not being output stage 11.9~ becomes a ,O’ potential and the red light
disconnected. The backgauge travels further to limit switch Al5 goes off too. Relay d15 and contactor Cl5 are dropp-
b9 and here the closer contacts open. Only now is the ed off.
,and’ condition within the ,forward on’ circuit reached The backgauge motor is turned off.
and the stop of the backgauge movement is actuated in The same occurs by releasing the Reverse Push Button b14:
the same manner as described before. The yellow light El4 goes off.
3.2.10.1
3.2.10.1 Backgauge forward
+2LV
i 032.1
FIXOMAT and lor

032.6 false clamp plate
DL3.11
STK65.111 ~L.65
STK 60.6/ LL.37
STK 61.71 L&.&S
1~ e3
0512 P13.2 1035/36 / %3$X P6.11
I.
-r ’ LZV-
,/D 5.4.1
ZA
./c75.7 r
Backgauge forword “I*
0d12
3.2.10.2
3.2.10.2 Backgauge reverse
2. t2LV
021.2
-. b13
021.5
STANDARD -7 D2O.L
.12
65.12 I Lb.73 STK 6O.L I IA.25
Standard and
automatic operation
II SC
-B--B--
STK 61.12 I LA.78

D25.12
DL6.8
?ae3
c77.9 055.2 P13.2
LZV-
Basic signal '0 “,

4
22 R3
Backgauge reverse
3.2.10.2 - 3.2.10.4a
The computer will not deliver any signal for forming the gizing the coil of relay dl 1. The test jack 22R5 shows sig-
,AND’ condition. nal ,I’ relay dl 1 pulls in and energizes contactor Cl 1.
Contactor Cl5 with one of its working contacts is swit- The normally closed contacts of contactor Cl1 open up
ching the table brake solenoid ml 7a on and the motor can and the express winding of the backgauge motor is dis-
turn freely. connected. At the same time, the working contacts of
As soon as contactor Cl5 drops off, the table brake sole- contactor Cl1 becomes closed and the slow winding of
noid m17a becomes disenergized and the table motor is the backgauge motor is switched in. With this arrangement,
stopped by the spring tension of brake assembly. the backgauge will move in slow motion and depending on
which other contactor Cl 2 or Cl5 is in the circuit, it will
be forward or reverse slow.
3.2.10.3 Backgauge Forward-Reverse slow in Standard If the backgauge is positioned in the area of the front limit
Operation switches and the reverse push button b14 is pushed in, then
In the immediate area of the front limit switch,the back- the reverse motion will be automatically in express since
gauge has to move forward in slow and in the area of the the computer did not have the information ,forward mo-
rear limit switch the motion should be reverse slow. tion prepared’.
In order to accomplish this, a number of other limit swit- Despite the Yellow Light E7 being lit up, the red Light Al 1
ches are located ahead of these respective and limit swit- will remain dark.
ches and when triggered, the switchover from express to Relay dll and contactor Cl 1 remain de-energized.
slow will go into effect. The same electrical procedure takes place if the back gauge
Function Limit Switch Switchover is positioned in the area of the rear limit switch and the
Limit Switch handwheel is pulled thereby engaging micro switch blob.
The computer had not received the information Reverse
Forward 9 7 Motion Prepared’ and the Yellow Light E13a indeed is lit
Forward By False 8 7a up. But the Red Light Al 1 remains dark.
Clamp Plate Inserted The backgauge will imediately start forward in Express.
Reverse 13 13a
Forward By Small 217 7a 3.2.10.4a Control of Backgauge Brake

False Clamp (Optional Feature) Standard Operation
Plate Inserted Machine is turned on, backgauge in resting condition. In
Forward With Pro- 217 7a this condition, the ground potential is connected via the
truded Fixomat (Optional Feature) normally closed contacts of micro switch b18a (hand fine
Layer Rakes adjustment assembly), relays d12, d15 and d122 to one
lead wire of the backgauge coil m19. The second wire of
As soon as the backgauge reaches the limit switch area, the the coil ml9 is directly connected to a DC voltage of ap-
switch 7 or 7a is bringing + 24 V to the input stage II.1 Ic proximately + 25 V. This voltage is produced from the 25
of interface card N-l regardless whether a false clamp plate V secondary output of transformer I and rectified within
is inserted and the limit switch b6 is normally triggered or a one way rectification system.
not. The brake coil ml 9 is immediately energized as soon as the
The + 24 V signal is transformed within the respective machine is turned on and with this, the backgauge is
koppler and acknowledged by the yellow light E7. braked.
The transformed signal is given to the computer via I I .25a. At the same time the brake coil becomes energized, the re-
Out of the individual information ,forward motion’ and lay d70 on card 22 in the C-Board is energized from +24V
,switchover switch 7 or 7a triggered’ the control signal via the normally closed contact of micro switch b18b and
,slow’ is now formed by the computer. connection I I .I 5c of interface card N-l. This signal is trans-
If the backgauge is in reverse motion and has reached the formed in the respective koppler and acknowledged by the
limit switch b13a, the + 24 V is put to the input stage yellow light E18. The information ,switch b18b not trig-
ll.lOa of card N-l. This signal is transformed within the re- gered’ is forwarded to the computer via I I .21 a for further
spective koppler and acknowledged by the yellow light processing.
E13a. The computer now delivers for the function , backgauge
The computer receives this signal ,switchover 13a triggered’ rest‘ the electronic signal ,brake secured’. This signal is fed
now via I l.26a and together with the other received infor- via ll.27a of the interface card N-l to a power pack unit
mation ,reverse motion’ a control signal ,slow’ is formed and trandformed to a useable + 24 V signal which then is
by the computer. put to the stage I I .5c of card N-l.
This output signal is fed to the card N-l via I I .29c and after The red light A70 will light up.
involving a power pack unit, the + 24 V output signal The control signal is connected to terminal 45 of card 22
,slow’ is brought to 11.6~ of card N-l. The red light All in the C-Board and used for the coil of relay d70.
acknowledges the electronic completion. Now the + 24 V Test Jack 22R 1 shows signal ,I ‘.
is connected to terminal 3 of card 22 (C-Board) for ener- Relay d70 pulls in and the ground potential is now also
3.2.10.3
,3.2.10.3 Backgauge forward and backgauge reverse slow
+ 2L v
b8
D21.9 0
b7
D20.7
Standard reverse
t
i STK 60.7 / L&.&3
Standard and I L-
fi= All
automatic opemtion
II 6c
w--a
STK 61.111 Lb.72
D 25.11
DL6.9
D55.2 P13.2 la35136 la33@ P6.11

\ - \
0 FL.1
2A L2 v-
-
Cl7 3
- ---
22.3
Basic signal “0 0
4 22R5
In slow “I”
2L v L
CT% DCX.3 05% P13.L P6.8

3.2.10.4a - 3.2.10.4b
connected to the coil ml9 by the working contact of d70 After the condenser discharge, a normal + 20 V is present
parallel to the contact seriesof b18a - d12 - d15-d122. on the Brake Coil.
If the backgauge is moved forward or reverse under power
by pulling the handwheel or using the push button bIllfor 3.2.10.4b Automatic Operation
reverse then the control signal ,brake secured’ is cancelled If the Automatic Backgauge is engaged by pushing in
by the computer after the respective information is pro- Button Fast , 3 ’ or Slow , 1 ’ then the computer is in-
cessed within. fluenced from the Keyboard Plate N-KB in such a way that
The + 24 V signal on stage 11.5~ of Card N-l will disappear. the table motor is switched on for Continuous Forward
The Red Light A70 will go out. Rotation. Naturally, this Continuous Motor Rotation does
Relay d70 drops off and Test Jack 22Rl shows ,O’ signal. not go in effect if any of the Front Limit Switches had
Since the relay dl2 (backgauge forward) and/or d15 (back- been triggered.
gauge reverse) are in the circuit for the backgauge motion, The Red Light Al2 will light up.
their normally closed contacts open up and the continuity Relay d12 and contactor Cl 2 are energized.
for the ground potential of the coil ml9 is broken. To prevent the immediate Forward Movement of the back-
The brake disk is released and through spring tension, the gauge (when automat is switched on), the computer still
backgauge drive becomes engaged. feeds the signal ,Brake Secured’ to the Interface Card N-l.
Pushing the handwheel of the hand fine adjustment device The Red Light A70 is lit up.
inwards will trigger the micro switches bl8a and bl8b and Relay d70 remains energized, the working contacts are
their normally closed contacts becomes open. closed and the ground potential to the Brake Coil is still
Micro Switch b18a opens the Ground Potential to brake connected, which means the backgauge remains braked.
coil m19. By pushing in Button Automatic ~ f ’ or, 1 ‘, a signal
Switch b18b at the same time, is switching off the + 24 V ,Automat On’ is given from the computer to the Interface
signal from 11.15~ of interface card N-l. The Yellow Light Card N-l Stage 11.32~. This signal is transformed within a
El 8 will go off. power pack unit to a usable + 24 V signal.
The computer, due to the received information ,switch The Red Light Al22 is lit up.
b18b triggered’ and ,automat off’ has cancelled the control The - 24 V signal on Output Stage I l.5a of Card N-l is fed
signal ,brake secured’ normally going to the interface card to Card 22 in the C-Board via the connection 44 to ener-
N-l. gize the Relay d122.
The Red Light A70 will go off. The Test Jack 22R2 shows signal ,I ‘.
Relay d70 drops off and opens the ground potential cir- Relay d122 pulls in, the normally closed contactsopenup,
cuit to the brake coil ml9 resulting in the brake disk to holding the circuit open via other open contacts of b18b
release. - d12 - d15 for the ground potential to the Brake Coil
Since the backgauge is also secured by the additional mo- m19. The working contacts of Relay d122 are holding the
tor brake, a micro switch b18c is triggered by pushing the Motor Brake Coil ml 7a in the energized condition.
handwheel inwards bringing the working contacts of this This arrangement is necessary to prevent any engagement
switch to a close and with it making a connection for 220 of Table Brake and Motor Brake during a directional change
V AC to the solenoid m17a (add. motor brake). The sole- of backgauge movement (Forward - Reverse) in the Au-
noid becomes energized and the motor can turn freely. tomatic Operation.
The backgauge can now be moved freely forward or reverse The de-energizing of Table Brake Coil ml9 in the Automa-
by the handwheel. tic Operation Stage, enabling the backgauge to move For-
The brake action is restored again if the backgauge mo- ward or Reverse, only takes place if a measurement, via
vement Forward or Reverse is interrupted or if the back- the numerical key board, has been fed in or was stored in
gauge is triggering either the forward or Rear Table Limit the memory bank as part of a specific program. The com-
Switch. The computer feeds out the signal ,Brake secured’ puter, having processed the information from switch posi-
via stage ll.27a of Card N-l. This signal is transformed to a tions ,Automat On’ - ,Micro Switch bl8b triggered’ (if
usable + 24 V signal, transferred via 11.5~ of Card N-l to handwheel is pulled) - ,Reverse On’ (if push button b14
terminal 45 of Card 22 located within the C-Board, and is pushed in) as well as the condition that a measurement
will energize then Relay d70. has to be complied with, can now produce the output sig-
The Red Light A70 will light up. nal ,Brake Release’.
Test Jack 22Rl shows again signal ,I ‘. The signal is cancelling out the power pack unit via Stage
The Brake Coil ml9 is put on ground potential as soon as ll.27a of Card N-l which before had the f 24 V signal fed
the working contacts of Relay d70 are closed. to the Relay d70 via 11.5~.
This arrangement (ground potential to the Brake Coil) has The Red Light A70 goes off.
the effect that the brake disk is pulled on fast and at once Relay d70 drops off and opens the circuit from ground
due to a discharge of the 50,uF condenser. potential to Table Brake Coil m19. The automatic back-
The 50 UF condenser was charged to approx. 170 Volt via gauge movement is starting. Instead of using the hand
the normally closed contacts at the time the d70 Relay re- fine adjustment device for the Forward or Reverse motion
mained in the Drop Off Position and the discharge is done of the backgauge, this same operation is possible by using
via a thyristor to have a very fast brake action. the Key ,==’ on the Numerical Keyboard.
3.2.10.4
3.2.10.4 Control of backgauge-table brake
LV + .V
X.6.10 D23.1
c3
b18
r --
i
L --
F DS2
DL6.7 D23.L D&l
D20.10 DL3.5
STK 61.6 I IA.39 STK 60.10 I Lb.62 STK65.51 LL.28
Al22 A’?
II 5a
-- -
STK 61.21 Lt.%
la37
025.2 ot 111
la.e2
DL6.6 D46.2 7aLOlLl - ,A la3889 P6.12 25vw
I ; - - P
C73.L
C7O.lZ
t C72.b 4C73.6
A utumc ON?” Brake r

_---
c
(
22.38
C72.6
0m17a 0ml9
C72.6
c70.10
i-
22ov-J
3.2.10.4b - 3.2.10.5
The computer will receive all the necessary information 3.2.10.5 Non Repeat Circuit
for the signal ,Brake Release’ this way too. Under these
conditions the brake is released after a cutting cycle. Test Jack Basic-Signal
If both cut buttons are depressed or the automatic knife
devise is selected, the computer still feeds out the signal 8Rl 1
,Brake secured’. This signal still remains in effect even when QRI 0
both cut buttons are released before the knife downstroke QR2 1
is completed or when the knife motion is stopped by break-
ing the light beam of the light barrier. This condition is Control Condition: Machine turned on, cut buttons not
made visible by a flashing decimal point of the digital dis- depressed. A + 24 V voltage is connected to the Relay Coil
play N-ISA ,Backgauge Stop’. of d230 via the closed contacts of both cut buttons b28a
If the knife has passed the lower dead-end point, the + 24 - b28b, the closers of Relay d73 (Automatic Knife N-MS),
V are fed to connection Il.lla of Interface Card N-l via the closers of Relay d37 (Light Barrier) and Gear Limit
closers of Relay d3 on Card 7SB and the working contacts Switch b22a as well as via the closed working contacts of
of Gear Limit Switch b22a as well as via the normally clo- Gear Limit Switch b22b.
sed contacts of Gear Limit Switch b22b. Within the Inter- Test Jack 8R 1 shows signal ,I ’
face Card N-l, this signal will be reconditioned in the re- Relay d230 will pull in since the pre-monitor stage output
spective koppler. of the Light Barrier has the signal ,0’
The Yellow Light E22 will light up. Test Jack QR 1 shows signal ,O
Since the clamp is still in the pressure applied stage,during Test Jack 9R2 shows signal ,I’
the knife cycle, and the Frame Limit Switch b29 is released, The energized Relay d230 switches the Light Barrier Emit-
its normally closed contacts are closed and the working ter Lamps h35b to ,ON’.
contact are open. This means that + 24 V are present on Relay d37 pulls in. (See functions under 3.2.10.6) The Re-
the Input Side ll.lOc of Card N-l, being transformed within lay Coil d230 remains on the + 24 V hook-up (via working
the respective koppler, and so acknowledged by the Yellow and holding contacts of d230 and d37) even if the closer
Light E29. contact of d37 becomes open.
However with this switch condition, the + 24 V signal will The switching time lag between opening of closer contact
be disconnected on the Input Side I I .I 5a of Card N-l. d37 and closing of working contact on d37 is being bridged
The Yellow Light E29ij is off. by a condenser 22,uF. This arrangement will prevent the
After return of the knife to the top dead position, the + 24 Relay d230 to drop off during the Pre-Monitoring check.
V signal which stayed on the Input Side I I.1 la of the In- The Relay d230 will drop off,
terface Card N-l via working contacts of Relay d3, working a) If the knife is on the upstroke, Gear Limit Switch b22a
contacts of Gear Limit Switch b22a, and normally closed being engaged by Cam (Closer Contact Open), Gear Li-
contacts of Gear Limit Switch b22b, is now taken away. mit Switch b22b has been released by Cam (Working
The Yellow Light E22 goes off. Contacts Open).
After the knife has been stopped in the Upper Dead Positi- Test Jack 8Rl shows signal ,O’
on, the clamp will now return also to the top position and b) If any malfunctions, during the Pre-Monitoring Check
will trigger here the Limit Switch b29. The exception is if are discovered.
the clamp is being held down by foot pedal. Test Jack QR 1 shows NO signal.
In triggering the Limit Switch b29, the + 24 V signal is be- During the Pre-Monitoring check of the Light Barrier
ing taken away from the Input Side ll.lOc of the Card N-l. Circuit, a short ,O’ signal will show up on the Test Jack
But will appear now on the Input Side Il.1 5a of Card N-l. QR2.
The Yellow Light E29 goes off and Light E296 goes on. The Relay d230 will come in again:
The computer will now form the signal ,Brake Release’ ba- a) If the knife has reached the Top Dead Position, the Gear
sed on the combined infeed information ,Knife Returned Limit Switch b22a has been released by the Cam and
To Top Dead Position’ and ,Clamp InTop Resting Position’. Gear Limit Switch b22b has been engaged by the other
The Red Light A70 goes out. The decimal point on the Cam.
digital .Backgauge Stop’ will stop flashing. Relay d70drops b) If the Cut Buttons b28a - b28b have been released, the
off and the Table Brake Coil is disenergized. The automatic Automatic Relay d73 is dropped off and the Light
movement to the next bakgauge stop position takes place. Barrier Relay d37 also dropped off. (During the Monitor
The brake will be switched on again (in Automatic Opera- Check after the Cut.)
tion) by a control signal ,Brake secured’from the computer c) If equipped with Hyd. Pressure Switch ,DS’. Plunger is in
after the processor has established the equation between Resting Position and Switching Stage is initiated.
the Read Out Measurement and the Actual Backgauge
Position ascertained by the Linear Measuring System in
connection with the Measuring Amplifier N-MAV and the
Counter N-Z. Naturally the brake afterrun is also being con-
sidered electronically and plays a part in the end result sig-
nal ,Brake Secured’ from the computer.
3.2.10.5
3.2.10.5 Non repeat circuit
only if equipped with hydl: pressure swish

OS.5 ,
I I ,/
I Dsl D4.L
I 0 DS ‘g)
I I
-----
JSTK 61.10 I u.a
---- _------- -- b 9.221
-- ---- ---- ----
Ii.
cl:
,’ 038.9 I
I
I
I q8
I
I
I
I
I
f-->-Tjem
L-- -------.A
I
------------1
_---
3.2.10.6 - 3.2.10.8
3.2.10.6 Light Barrier Amplifier 3.2.10.7 Time Limitation Control

The time limitation circuit within Card 8 at the D-Base
Test Jack Basic Signal has the purpose to release a cutting cycle only, if both Cut
Buttons b28a and b28b are pushed in simultaneously. This
LSF Gl 0.12 V max. arrangement prevents any tampering within the cutting
LSF G2 0.12 V max. Checked with cycle release, (such as blocking one cut button permanent-
LSF G3 0.12 V max. D ignotest ly and starting the cut with the other button). A + 24 V
9R4 0 voltage is connected to the normally closed contacts of the
2 Cut Buttons b28a - b28b and wired from here to the
Average Testing - Check Values: 0.07 - 0.08 V. input terminal 3 of Card 8. This voltage is fed to a switch
transistor via a voltage splitter. The switch transistor, if
Test condition: voltage is present on the input stage, produces a O-V po-
Machine turned on, Relay d230 pulls in. tential which, in this case, is fed to the coil of Relay d305.
(See under 3.2.10.5) Relay d305 pulls in and the working contacts become clo-
Light Emitter Group h35a all bulbs lit up. sed. In pushing the 2 Cut Buttons b28a - b28b, the + 24 V
The working contact of Relay d230 is switching + 24 V to signal will disappear on 8.3 via the closer contacts of Cut
the Relay coils of d230a and d230b. Other working con- Buttons b28a - b28b. The switch transistor remains energi-
tacts are switching 5.8 V or 6.2 V (Depending which trans- zed via a self-holding contact of Relay d305 and the Relay
former tap is used) to the Emitter Light Group h35b. d305 stays pulled in.
The respective fotoelements are exposed. The fotoelements The other 3 closed working contacts of Relay d305 are
1 - 6 (in pairs) are connected in series and are controlling used to control the oscillator stage at the cutting circuit.
3 transistor stages against the O-potential. If the fotoele- If only 1 of the cut buttons is pushed in, the + 24 V signal
ments are fully illuminated, the checked voltage on Test on 8.3 will disappear due to an open circuit in this line.
Jacks LSF Gl -G2 - G3 should be as low as possible. (Not On Terminal 8.30 no + 24 V signal will stay on as the work-
more than 0.12 V.) A low voltage condition has the effect ing contact of the one cut button not being pushed in,
that from the output stage of the amplifier on Card 9 and holds this circuit open.
on the Test Jack 9R4 a ,0’ signal will show up. No more + 24 V is coming via the holding contact of Relay
Relay d37 pulls in against 0 V. d305 to the voltage splitter.
The working contact of Relay d37 is switching the Pilot After the Condensator 22 PF has discharged, the switch
Light h34 to ,ON’. transistor will go over to the blocking stage.
if the light beam is broken, the following datas are to be Relay d305 will drop off. The working contacts become
checked on the Test Jacks: open.
If now, at this time, the second cut button is pushed in,
Broken Light Beam Test Jacks Signal the Relay d305 will not become energized anymore and
the cutting cycle is blocked.
1 or4 LSF 61 0.5 V min. A cut release will be impossible.
2 or 5 LSF G2 0.5 V min. A new cutting cycle will only be possible after both Cut
3 or 6 LSF G3 0.5 V min. Buttons b28a - b28b have been fully released and again
pushed in.
Average Testing - Check Values: 0.7 - 0.8 V. The condenser, being hooked up to the voltage splitter, is
value selected in such a way that he will keep the switch
If one or more of the light beams are broken, then a ,l’sig- transistor in the operating stage for another 0.5 seconds
nal will show up on the common output stage of the am- after the + 24 V signal disappeared from the Terminal 8.3.
plifier as well as on the Test Jack 9R4. Within this lapse, the working contacts of both Cut But-
Relay d37 will drop off. tons b28a - b28b have to become closed in order to allow
Pilot Light h34 will go out. a new cut release.
During the cut release, using the two Cut Buttons b28a -
b28b or with the automatic knife Relay d73, a monitoring
check of the light barrier system and circuit is done auto- 3.2.10.8 Cutting Circuit
matically each time, by bringing the O-potential to the ba- The control for the downstroke motion of the knife isgiven
sis of the 3 transistor steps located on the fotoelement with the Cut Button b28a and b28b.
board LSF. + 24 V is fed to the Input Terminals 30,31 and 39 of Card
The Test Jacks LSF Gl - G2 - 63 should show at least 0.5 V. 8, via the closed working contacts of the cut buttons.
Relay d37 has to drop off. Herewith the following conditions have to exist:
Pilot Light h34 has to go out. a) Light barrier should not be interrupted(working con-
Test Jack 9R4 should show ,I’ signal. tact of Relay d37 is closed).
If Relay d37 is energized, then the Yellow Light 037 on b) If the machine is equipped with the retractable side
Card N-MS (Automatic Knife) located in theupper control guide, this unit should not be in the ,ON’ position (nor-
panel, will light up. mally closed contacts of Relay d303 are closed).
3.2.10.6
3.2.10.6 Light barrier
.-
‘I
S,B-sp-
r-‘-‘-~
ov
/ ,~ijiJ++ 1
i (dlJ0) --/
*2Lv ~
d/i0
------L-_8_1:
3.2.10.7
3.2.10.7 Time limitation control
2L v
+ 24 v
+2LV ---
D 4L.5 D L9.9
D-5 5
I
!
/
I
L --- 049 7
D LL,L
I
L----
DSf.
DLL.3
D 31.3
D 3L. 12 8704
L
-m-w------_ -I 3
8 70.3
D 3L.5
D3L.6
@Ij$)
1 870.1
4; ____ -__------------_
57b.3
87 b.L
t D35
STK
D3L
870.6 96101 10 / L4.64
D34.8
3.2.10.8 - 3.2.10.9
If the machine is not so equipped, then the connection The oscillator will stop oscillating if both Cut Buttons b28a
D49.7 and D49.9 have to be bridged. - b28b are released or if the light Barrier Relay d37 drops
Within Card 8, additional conditions have to exist in order off. The voltage induced in the secondary winding of
to provide the electrical control circuit for the oscillator Transformer M is eliminated. The hydraulic solenoid be-
cycle: comes disenergized and the valve opens up.
a) Non repeat circuit ,ON’ (working contacts of Relay A quick and immediate drop of pressure in the working
d230 are closed, see 3.2.10.5). cylinder for the clamp and on the hydraulic clutch for the
The monitoring check within the light barrier system main drive is the result. Clamp and knife are stopped
shows ALL O.K.’ suddenly. The computer however, takes notice that the
b) Time limitation control ,ON’ (working contacts of Re- cutting cycle has not been completed and the decimal
lay d305 closed, see 3.2.10.7). point within the display keeps on blinking.
c) The computer output signal should not read ,Cut Cycle Whenever the knife has passed the lower dead end position,
Blocked’ based on ,Backgauge Is In Standstill’, ,The a cam on the gear will trigger the limit Switch b22a and
Previous Cut Cycle Had Been Completed’, ,The Clamp another gear cam (negative cam) releases limit Switch b22b.
Is Back To The Upper Dead Position’ after the previous The agitation of the oscillator circuit is now done through
cut. the closed working contacts of Relay d3 on Card 7SB (see
The control signal ,Cut Blocked’, coming from the Out- 3.2.10.9) and of limit Switch b22a as well as through the
put Stage ll.9a of Interface Card to the Input Terminal closers of limit Switch b22b via the Terminals 29 and 32
34 of Card 8 and will here be acknowledged by the on Card 8.
Light A8.34. If the machine is equipped with a pressure switch, the
If all conditions are met for the electrical control circuit additional condition requires that the pressure switch
to the oscillator the latter willstartoscillating.The generated tappet moves outward and triggers the output stage elec-
frequency, within the output stage, controls alternately tronically. Failing this sequence, the knife will stop imme-
2 power transistors, which are also alternately connec- diately after passing the lower dead end position.
ting the 0 V-potential to the primary side of a transformer The closing and respectively opening of contacts within
via 8.1 and 8.2. The transformer M is located on the D-Base. the limit Switches b22a and b22b will disconnect the Re-
The transformer primary winding has a center tap connec- lay d230 on Card 8 (see 3.2.10.5). The agitation of the os-
ted to + 24 V via the control for safety bolt on Card 7SB. cillator through the limit Switches b22a and b22bwill stay
(See 3.2.10.9) on until the knife has reached the upper dead end position.
Thru the alternating connection of both winding ends to At this time, the positive cam will release limit Switch b22a,
the 0 V-potential, an alternating voltage is produced in whereas the limit Switch b22b becomes engaged through
the primary winding of the transformer which in turn pro- the negative cam. In this position the working contact of
duces an inductive voltage of approximately 50 V in the limit Switch b22a and the normally closed contacts of
secondary winding. b22b open up. The agitation of the oscillator is stopped.
This voltage is fed via Terminal 18 and 19 back to Card 8 The knife movement is stopped by disengagement of the
for rectification. hydraulic clutch. The Test Check Point 8R2 shows the ba-
The now rectified voltage of 42 V is transferred via a switch sic signal ,I’. The Yellow Light E8.20 goes off.
transistor to Terminal 16 and 17 and hooked up to the hy- With the clamp in its upper most position, the decimal
draulic Solenoid m27. point within the ,Backgauge Stop’ display will stop blink-
This solenoid becomes energized and opens the valve for ing.
oil flow and pressure built up in the working cylinder for
the clamp as well as the engaging of main clutch for knife 3.2.10.9 Safety Bolt
drive. The safety bolt device in its resting position is blocking up
Pressure and cut takes place. the downward motion of the knife. It has to be taken out
At the time the oscillator starts oscillating, an additional of this position before start of the knife cycle.
transistor is agitated against 0 V-potential. The respective If with the Cut Buttons b28a - b28b depressed, or in using
O-signal can be checked on the Test Point 8R2. This signal the automatic knife feature, all conditions are met to agi-
is fed via Terminal 20 of Card 8 to the automatic knife tate the oscillator of Card 8. (light barrier on - time limi-
Card N-MS in the upper control panel for information to tation observed - non-repeat circuit clear - cut O.K’d
the computer that a cut has been released. The signal is be- from computer), then a + 24 V signal from Terminal 37 of
ing acknowledged by the Yellow Light E8.20 on Card N-MS. Card 8 is being transferred via the normally closed contact
At this time the decimal point within the ,Backgauge Stop’ of limit Switch bSB (on safety bolt device) to connection
display will start blinking. 34 on Card 7SB. With this condition met, the Relay dl
The 0 V-Signal on E8.20 is also connected to Terminal 36 will become energized.
of Card 7SB and thereby allowing Relay d302 to become The working contact on dl closes and energizes Relay d2.
energized. The normally closed contacts open up and the The Relay d2 holds itself through its holding contact and
functional circuit for hydraulic lifts as well as the retrac- the normally closed contact of Relay d3. Two working
table side guide becomes open, preventing the engagement contacts of Relay d2, connected in parallel, are switching
of both. 42V to the safety bolt Solenoid mSB. The safety bolt now
3.2.10.8
3.2.10.8 Cutting circuit
Only with re~racioblc side gauge
+zr,
I ;
0d303
870.L
4
3
870.3
D3L.5
Compuler
D3L.G
0b28b 976.3
3
w
I-------- ---- 1
87b.L
t 038 .I2
l .* IT.320
D3L.8 I
I L
I
I 1 1
2LO.2
I
pn-~
0d37 *
II
9 LO.9
I
I
I I
xx. 9 0 /
-- L----
i--- 1
, 8.39 8.31
I STK 61.5/L&33
0d305 _--
c, /
d230
I
I
I
I
I
025.5
I
I
1 I
I
I
I
I
I I
834 ’
I I
I I ’
+2LV t
L-- ------
I u.71
i----- ---------- i
051.
3.2.10.9 - 3.2.10.10
is being drawn back to clear the path way of the knife With release of the foot pedal, the resting contact of Switch
carrier. The limit Switch bSB is triggered at this stage b 309 opens up again. Relay d312 remains energized and
bringing the normally closed contacts to open and Relay is holding conical valve solenoid in the energized stage for
dl drops off. The working contact of dl become closed now, until the clamp has reached the uppermost position
and with another closed working contact on Relay d2, a where the limit Switch b29 becomes triggered. Its resting
voltage of + 24 V is being connected to the center tap of contact opens and the self-holding of Relay d312 is inter-
the Transformer m. This arrangement, pulling the safety rupted. Relay d312 drops off in a retarded way and coni-
bolt back and involvement of the limit Switch bSB, is an- cal valve Solenoid m315 is switched off.
other required condition for a cut cycle release. The built-in retarding is necessary to allow the clamp to
Relay d2 remains in the energized stage until the knife has reach the upper most position during the suppression range.
passed the lower dead end position. Test Jack 8cR3 shows again signal ,O
The working contact of gear limit Switch b22a and the Relay d312 becomes energized when both cut buttons are
closer of limit Switch b22b become closed by the gear pushed in, providing all other necessary conditions are
cams at this time. A voltage of + 24 V is now connected met for a cut release:
to the coil of Relay d3 via the still closed contacts of Re- Light barrier ,ON’ - Non repeat circuit ,ON’ - ,Time limi-
lay d2 and limit Switch bSB. Relay d3 will pull in, its clo- tation has been observed’ - Signal from computer ,Cut
ser contacts open, Relay d2 drops off and the 42V for the O.K.‘.
safety bolt solenoid is dieconnected. Test Jack 8cR4 shows signal ,I’
The working contact of Relay d3 is holding the + 24 V One working contact on Relay d310 connects O-potential
needed for the agitation of the oscillator on Card 8, via to the coil of Relay d311.
the closed contacts of limit Switch b22a - b22b and for Relay d311 becomes energized since + 24 V is already
the center tap of Transformer m, maintained so that the connected to the other end of the coil thru the closed rest-
knife can return to the top position. ing contact of Relay d313. Relay d311 pulls in and is
The safaty bolt is baing pushed into the initial position by holding itself with the O-potential over a closed working
spring tension. If limit Switch b22a is released by the posi- contact on d311.
tive gear cam and limit Switch b22b is triggered by the ne- Test Jack 8cR6 shows signal ,O
gative gear cam, then Relay d3 becomes de-energized due Additional working contacts on Relay d310 and d311,
to the now open contacts on both limit switches. connected in series, bringing + 42 V to the conicle valve
In case the safety bolt mechanically becomes stuck in the Solenoid m315. The valve opens and pressure is applied to
initial blocking position or even in the drawn out position, the working cylinder.
any other cutting cycle is impossible. In both instances, If the knife motion is interrupted between the upper and
the Relay d2 will not become energized. the lower dead end position, i. e. by release of the cut but-
tons or breaking of the light barrier beam, then Relay d310
3.2.10.10 Conical Valve Control drops off and the conical Valve m315 becomes disenergi-
zed too.
Test Jacks Basic Signal Test Jack 8cR4 shows signal .O’
The hydraulic oil return flow, out of the working cylinder,
8cRl 1 is blocked now and the clamp remains in the position it
8cR2 0 had when the cut was interrupted.
8cR3 0 If now the foot pedal is used the clamp will go down under
8cR4 0 safety pressure but Relay d312 does not becomeenergized
8cR5 1 due to the open contact of Relay d311 and with it the
8cR6 1 breaking of the O-potential to the coil of Relay d312 takes
place. After release of foot pedal again, the clamp will
Condition on machine: Machine turned on, cut buttons remain right there where it was at that time.
not depressed, foot pedal for clamp If the cut is continued, by pressing both Cut Buttons b28a
not stepped on. - b28b, then Relay d310 again becomes energized and
Parallel to coil of Relay d230 (Card 8) a + 24 V voltage is the conicle Valve m315 too is shifted. The full pressure
put to coil of Relay d314 again stays on within the working cylinder. After the knife
Test Jack 8cR 1 shows signal ,I’ has passed the lower dead end position, both gear limit
Stepping on foot pedal releases Switch b30Q. This will re- Switches b22a - b22b are triggered and Relay d314 will
sult in energizing Relay d312 via the closed contact of drop off.
b309 and the closed working contact on Relay d314. Test Jack 8cR 1 shows signal ,O’
Test Jack 8cR3 shows signal ,I’ Also Relay d310 and the conicle valve Solenoid m315 are
Relay d312 is now switching + 42 V to the conicle valve disenergized at this time.
Solenoid m315. The clamp starts to come down under sa- With the change-over contact on Relay d314 and the closed
fety pressure. Limit Switch b29 becomes disengaged. The working contacts on limit Switch b22a and Relay d3 (Card
resting contact closes and Relay d312 is holding itself via 7SB), the condenser, connected parallel to coil of Relay
its working contact. d313, is charged up at this time.
3.2.10.9
3.2.10.9 Safety bolt
7e 1
2A
?eZ
2A
.----- +--1
0dl I I
0dl
0V ---- a~I
I
li733 I
7RL
0~
mSB
t
---
D LO. 6
0D6.93
LO.9
r
m I
3.2.10.10a
3.2.10.10a Clamp:
Conical valve control by foot pedal operation
D23.1
D23.L 055.9
D20.10
1
STKGO.10
Lb.62
8C.Ll
‘r 8c.13
- -- .----I
8~32
(m31;) cmical wlbe
8c.23 05 1.5
3.2.10.10b
3.2.10.10b Clamp:
Conical valve control by cut
*24v + 24V +24V
.22 ’ 13.9
) 55.9
8c.30
---cBc R5
8.3g (d3n) [ l-
-- -- -0-
i
8.37
8dO
t
__-- - -- - __- --
d 310 .8c .32

I
.D 51.6
(d311)
ta3 I conical
. D51.5
valve
i
i =
.
r2lV + 2LV
8~22 )23.1 P 13.9
c=
b29 123.4
020.10
-- D 15.9
---CM==
(ZZ) (ZZ) D38.10+7
8c.Rl I
EC.29
8.Rl 3-
i I t5V EC.30
L L-------J
(d21;;)
--
.
EC. R6 )--“----J
lod312
D51.6
(ZG) conical valve
051.5
3.2.10.10 - 3.2.10.12
If the knife has reached the most upper dead end position, will stop blinking. The display Automatic Knife’ however
Relay d314 will pull in again and will still keep on blinking.
Test Jack 8cRl will show signal ,I’. If the next backgauge stop position has been cleared by
lhru the switch-over contact on Relay d314 the before the computer, then the backgauge will travel in this direc-
mentioned condenser becomes now discharged toward the tion and after reaching the respective measurement,
coil of Relay d313, resulting in a quick pull-in of this within the allowebel variation, the Relay d73 becomes
d313 Relay. energized and Red Light 073 will light up.
Test Jack 8cR2 shows signal ,I’ The oscillating stage for the oscillator on Card 8 is now
The switch-over contact of Relay d313 is switching Relay turned on without pressing of both Cut Buttons b28a -
d312 to ,ON’ and Relay d311 ,OFF’. The Relay d312 is b28b.
switching the conical valve Solenoid m315 ,ON’ again and If the backgauge has to make a reverse movement after a
is holding itself via the closed resting contact of limit finished cut, as per the computer readout, then the auto-
Switch b29 until the clamp is back to the upper most po- matic knife cycle is turned OFF.
sition. The following conditions also turn off the automatic
knife cycle:
3.2.10.11 Automatic Knife Interruption, breaking of the light beam (electric eye),
The automatic knife feature becomes prepared if the Key Light barrier monitoring check negative,
# u ‘ on the upper control board is pushed and with si- Backgauge has reached forward front limit switch,
multaneous pressing of both cut buttons the automatic Pressing of key , q ’ (Automatic Knife OFF),
knife cycle is started. Exceeding the measurement tolerances allowed to a mea-
The following conditions have to exist: surement backgauge STOP,
Light barrier ,ON’ (d37, Card 9; Yellow Light D37 Pre-recorded signal ,Automatic Knife OFF’ stored within
on Card N-MS has to be lit up) and to a specific backgauge STOP.
Time limitation has The resting contact of Relay d73 is incorporated in the
to be observed (d305, Card 8) normally closed contact circuit of Cut Buttons b28a -
Non-Repeat ,ON’ (d230, Card 8) b28b toward Relay d230 on Card 8.
Light barrier If for any reason, during the upstroke of the knife, the
pre-monitored O.K. (Test stage on card 9 d230, Card 8) Relay d73 does not drop off, then Relay d230 remains
Backgauge automatic ,ON’ by pressing key , $ ’ or, x ’ unenergized and with this condition the oscillator on Card
Backgauge in standstill, computer has not blocked cut cycle 8 will not go in oscillation. (See 3.2.10.5)
Backgauge has not yet reached front limit position (b8 -
b9 - b217). 3.2.10.12 Air System Control
The display light ,Automatic Knife’ is not defect. Pushing the Switch b87 Air ON’ brings a + 24 V signal to
In pressing the key , q ’ the computer receives the signal the connection Terminal I I .12c on Interface Card N-l. This
to become activated and utilize the before-mentioned con- signal is here transformed within the respective koppler
ditions. If all is positive, the display light ,Automatic and acknowledged by the Yellow Light E87. The transfor-
Knife’ will light up in a permanent way to acknowledge med signal is now fed to the computer, via connection
the readiness. Terminal I I .30a, and the powerstage of Interface Card N-l,
If both Cut Buttons b28a - b28b are depressed, the oscil- via connection 11.31, is activated.The Relay d88 pulls in and
lator on Card 8 becomes agitated (See 3.2.10.8) and starts the Red Light A88 goes on. The working contact on Relay
oscillating. d88 closes and connects + 42 V, via Terminal I I .2c of the In-
Test Jack 8R2 shows signal ,O’ terface Card N-l, to the Solenoid m94 of Air Blower m93.
The safety bolt is being pulled back (See 3.2.10.9) The control signal ,Air ON’ is also automatically given by
The Yellow light K8.20 on Card N-MS will light up. the computer every time the backgauge is in reverse motion,
Relay d73 on Card N-MS is being energized. during automatic backgauge, or if the additional function
The Red Light 073 on Card N-MS will light up. Air ON’ has been recorded in conjunction to a specific
The display light ,Automatic Knife’ as well as the decimal backgauge position. Relay d88 is turned OFF if one or both
point within the backgauge stop measurement display will cut buttons are touched. If the automatic knife feature is
start blinking. engaged, then the Relay d88 becomes disenergized by the
The working contacts of Relay d73 are closing and the cycle after the automatic cut. In both instances, opening of
connection, parallel to the working contacts of Cut But- the resting contacts on Cut Buttons b28a - b28b and open-
tons b28a - b28b is made to the oscillator on Card 8. The ing of the resting contact on Relay d73, the + 42 V signal
cut cycle is continued automatically even after the cut within the infeed of Card N-l will disappear. The Yellow
buttons have been released. Light E28 goes OFF. In circuit, after the respective koppler,
After the knife has passed the lower dead end position a signal ,O’ will emerge to be fed to the computer.
and the gear limit Switches b22a - b22b have taken over The computer responds and blocks the ,Al R ON’condition.
for the knife upstroke, Relay d73 will become disenergized. The Red Light A88 goes OFF. Relay d88 DROPS OFF.
If the clamp has also returned to the uppermost position The working contact of Relay d88 opens and disconnects
then the decimal point within the backgauge stop display the voltage to Solenoid m94. The air system is turned OFF.
3.2.10.11
3.2.10.11 Automatic knife
+ 24v +24V +24v +24V

038.11
DL5.L
I STK65.6
L&.3L,
D22.9
DU.1 (
-- J
y-i-1 t
1L3.l D20.10 Gb3.5 D20.6
r --y--k+-- I
I
I
,8.39 18.3
I
, 8.30
?K65.l/L4.1
r
~TK'JO.10/&62
--
II IOC
i
STK 65.5/LUB
--
II lla
1
---l----l
STK6Q6
1113a
1L4.37
Basic signal’l”
8R2
I by cut’0”
D51.3 s'D51.2
- Backgauge
0m27
i
--I - Backgauge
reverse
3.2.10.12
3.2.10.12 Air system control
D3L.12
c3
b28
D31.L
33L.7
b28
q+
D3L.9
D25.10
1
STK60.121 Lb.76 STK61.lO/L1.64
--
IllZa J
--
Air automatic
STK 6L.G n ic
+1zv
LL.35
I
6
1
0 d88
I -- STK 60.9 1 Lb. S5
D20.9
I----- 0313
0m94
i D33.1
i
3.11 -3.11.3
Under load - control panel connected (Air on or clamp in

3.11.1 Instruction for Voltage Adjustment down position). This voltage will go down to the appropri-
3 Voltages are adjustable on the cards, within the P-Board, ate value of approx. 42 V - 48 V.
using the respective potentiometers.
3.11.2.2 Machines with Central Plug (Plug L4)
Voltages Application Adjustment on: Measurement directly on the plugs
Contact pins L4,26, 23,38 (+) 5 V, adjustment
5 V Supply Voltage for IC’s SK 2a against 5,4 V - 5,45 V with potentio-
24 V Supply Voltage for Relays etc. SK 3a Contact pins L4,5, 20 tow meter on SK 2a
5,5 V Supply Voltage for 7 Segm. Displays SK 4a This voltage should be set somewhat lower at the very be-
ginning and only thereafter adjusted to the exact specifi-
2 Voltages are factory pre set and should only be checked. cation as per instruction under 2.2a
Contact pin L4, 2 (+I 5,5V, adjustment
Voltages Application Remarks against 5,5 V - 5,6 V with potentio-
Contact pin L4,23 (OV) meter on SK 4a
- 6 V For D-Board Safe-. Test Jack on SK 3a against 0 Contact pin L4, 16 24V adjustment
ty Lock Voltage (Yellow Jack) against 235 V - 24,5 V with potentio-
42 V For Solenoids on SK 4a - against ground Conatct pin L4,23 meter on SK 3a
(Red Jack P-Board) Contact pin L4,35 42V This volta-
against approx. 70 V - 75 V ge has to be
All Voltages, except 42 V, are based on O-potential (yellow Contact pin L4,53 checked only,
Jack on P-Board). not to be adjus-
ted.
3.11.2 Voltages with disconnected control panel but ma- Under load .- control panel connected (Air on or clamp in
chine turned on. down position). This voltage will go down to the appropri-
This check procedure is most likely used any time a con- ate value of approx. 42 V - 48 V.
trol panel is changed or the P-Board was replaced. The
purpose is to establish and check the max. allowable vol- 3.11.2.3 Measurement on P-Board
tage. The voltage datas are of reference value. Re-checking of voltage - 6 V on P-Board SK 3a (upper
The plug connection between control panel and machine Test Jack). Voltage range from - 5,4 V to6,6 V (6V k 10%)
have to be detached.
Important: On control panels with Card N-F (Fixomat). 3.11.3 Measurement with control panel hooked up,
These plug connections also have to be disconnected
connected. All plugs from control panel to the machine should be
All voltages are to be checked with a digital voltmeter ha- plugged in and machine should be turned on.
ving a display figuration of 3 l/2 digits. (These digits should Reference point should be scanned.
register from - 1999 to + 1999 counts.) Measurement done on the 2 Test Jacks (2 mm 0 ) of Card
N-MAV. (upper part of control panel)
3.11.2.1 Machines with Mate-N-Lok Plugs Blue Test Jack: ov on the right side
Measurements directly on the plugs Red Test Jack : + on the left side
Plug No. 68 (This voltage should not go over 5,15 V even for a short
Contact pins 4,5,6 (+) 5 V, adjustment period of time)
against 5,4 V - 5,45 V with potentio- During adjustment on the potentiometer of Card SK 2a
Contact pins 1,3, (0) meter on SK 2a attention should be given to this fact and the exact voltage
This voltage should be set somewhat on the lower side at level should be reached by slowly increasing the voltage
the beginning and only thereafter adjusted to the exact from the low level starting value.
specification according to instruction under 2.2a
Plug No. 64 Voltage on Card N-MAV: 5,lO v - 5,15 v
Contact pin 1 (+) 5,5V, adjustment
against 5.5 V - 5,6 V with potentio- Important: For establishing the starting value of 5 V only
Contact pin 4a (0) meter on SK 4a the voltage on Card N-MAV is of importance.
Contact pin 3 (+) 24V, adjustment All other values as on P-Board - SK 2a and
against 23,5V - 24,5V with potentio- control panel are for guidance only.
Contact pin 4 (0) meter on SK 3a On older cards (without the test jacks) thevoltage is checked
Contact pin 6 42V. This volt; directly on the diodes of Card N-MAV.
against approx. 7OV-75V ge has to be (Attention: Do not shorten circuit accidentally)
Contact pin 9 checked only, Measurement done on the Banana Jacks (4 mm 0) lower
not to be adjus- part of control panel (Base Plate). On the left side of control
ted. panel (Fixomat section) the following testjacksare located.
3.11.3 -3.11.9
Color Voltages Measurement against OV On control panels with a cover both check points are mark-
ed with ,B’.
Blue ov - Push in key ,total cut / memory retrieve button’
Red 5V 5,25 V - 5,40 V Guidance The afterrun should now be visible in the backgauge stop
Yellow 24 V 235 V - 245 V value display
In the center of the control panel within the lower part Distance reading 0,4 mm - 0,7 mm
one more banana test jack is located Remove wire jumper
Green 5,5 v 5,20 V - 5,50 V Guidance Testing the brake afterrun, upper control board with
value EPROM dated 6.7.1979.
Measurement done on the Test Jacks (2 mm 0) on the Look by table brake no. 2.6.10 part 3.
P-Board
On Card 2a 3.11.7 Checking interchangeable memory bank
Voltages Measurement value Touch key , !! ‘. Bring to number 99 in the program
5V 5,30 v - 5.45 v Guidance value display 6.
On Card 3a Touch key ,Program with cut and prepare erasing’ as well
-6V - 5,4 v - - 6,6 v as key ,Erasing’ ( X ). A short whistle sound will be no-
Guidance value
24 V 23,5 V - 24,5 V ticed indicating that the memory bank has been complete-
On Card 4a ly erased.
5,5 v 5.2 v - 5,5 v Touch key ,Available cuts’ ( -i- ). The display 7 (Still avai-
Guidance value
42 V 70 v - 78 v lable cuts) should show the number 512.
Touch key Program with cut and prepare erasing’ again to
Remarks to the voltage of 42 V: release position.
Since this voltage is not stabilized, a large difference is to
be noticed in the voltage level between condition ,under 3.11.8 Recording of backgauge positions in the memory
load’ (e. g. hydraulic lift on, clamp in down position) and bank
during ,idiing’ (e.g. control panel not connected). By touching key t: program selection brings number 1 into
This is a normal condition and in no way critical. display.
If the voltage of 5 V, measured directly on P-Board SK2a, In the display ,Still available cuts’ the number ,0’ should
shows a large trend to a higher value (approx. 0,l V above shown indicating a free memory bank.
the proper voltage). A check is to be made whether all Touch key ( q ) ,Program recording’. The present back-
electrical connections, normally in parallel fashion, are gauge position is recorded in the memory bank and is visi-
properly hooked up. ble on the display ,Backgauge stop’. A short whistle sound
Plug 68 4,5,6 for (+5 V) indicates that the recording has been complete.
Plug68 I,3 for ( OV) Bring backgauge with handwheel in 2 other positions and
Central Plug L4 record same in the memory bank.
L4 26,32,38 for (+5 V) For checking purpose touch key Available cuts’ ( -j- ).
L4 5,20 for ( 0 V) The display 7 should read now ,509’.
Check erasing of a recorded measurement:
3.11.4 Checking connection between ground and 0 V Select the second cut and touch the key ( X ) erasing.
No continuity should exist between machine ground and Pay attention to the short whistle sound. The second cut
the 0 V-potential of the power supply. of program 1 should now be erased from the memory bank.
For a proper check of this condition use a Ohm-Meter The following cut in program 1 will automatically switch
(Multimeter) and connect the Red and Yellow Test Jack to the next sequence number down.
(4 mm 8) located on the P-Board. For checking purpose touch key Available cuts’ (e-j-).
If the machine is turned off, the resistance reading should The display 7 Still available cuts’ should now read ,510’. If
only be very high in Ohms (A few Mega Ohm infinite). key Available cuts’ ( -j- ) is released the display 7 will
read 2.
3.11.5 Indicator Light Test
Turn on the machine incl. control panel power. 3.11.9 Erasing of program in the interchangeable memory
Reference point not scanned and reached bank
Push in key ,automatic backgauge off Touch key $ . The display 7 should show number 1.
All lights should be lit up, all segments of the display area Touch key ,Program with cut and prepare erasing’ ( L& ).
should be lit up. (Exception: Light ,Automatic Knife Pre- Touch key ( X) erasing.
pared’ and all lights and displays for Fixomat.) Pay attention to the short whistle sound.
After a few seconds the light test indication will go off. Program no. 1 has been erased.
In the digital display 7 the number ,0’ should show.
3.116 Checking the Brake afterrun Touch key -i- for display of Available cuts‘. The digital
Connect the two check points on the right side of Card readout has to show ,512’.
N-KB with a wire jumper. Touch key tix ,Program with cut and prepare erasing’
3.11.10
3.11.10 Checking backgauge stops (wi~out correction de- Measurement differences: should be
vice) on program 5 0,Ol - 0,03 mm
To select ,Without correction device’ flip switch on key- Repeat same procedure with all other recorded
stops and
board card (upper control panel) compare both displays.
With tipping of key ! ,Program Selection’ bring number With backgauge in position 4,000 cm, attach a magnet base
98 to the readout display. test indicator to the table, align to front surface of rake
Record program (sample) and bring indicator handle to 0.
With key ( i ) ,Memory Space selector’ bring to memory Repeat the full program in automatic 3 times over and
space 1. compare each time the reading of the test indicator with
With key ( 3 ) ,Forward Express On’ switch on automatic. the read out on display ,Backgauge Position’ at the 4,000
Touch key ( q
) ,Automatic Start’ to start forward mo- cm backgauge position.
vement. The backgauge will move to the first cut recording. Flip the small switch on the right side of the keyboard card
Compare the digital read out on display .Backgauge Posi- (upper control panel) back to position ,With Correction
tion’ to display ,Backgauge Stop’ Device’.
Push key ,O’ for ,Automatic Off’.
POLAR -MOHR E-MC

Kunde : Rijfprogromm115
customer: testing program115
Auftrag Nr:.firr Punkt 12 3 1 Progromm Nr.: 93 (ohne Korrektur)
order no. : for point 12.3 I program no :98 (without correction)
IIIET f / m:gure ~xIB’Z~ u+$$Fi z j 5 ,“i X x b c-7 - - g % .w. 0
I
f / I I I I I I //II I
1 x 11/I j5~OjOjO~ X
2 II '010opp IX
3 ) 9198pb
L / sjoo~io~ / 1 1 / I :
5 j G/9 8/Op/ / / / x
8 Schnltte
8 cuts
I I
,- -_2__--- - -- ------b-J
3.11.11 -3.11.12
3.11.11 Checking of Numerical Keyboard and Calculator Push again each key to turn off pilot light.
unit Recording of additional stop mark to established program
Check in sequence all numerical keys 1 - 2 - 3 - 4 - 5 - 6 - 7 q .
- 8 - 9 - 0 and check against the readout display ,Backgauge Touch key lfsl for display ,Backgauge Position’ to ,Back-
Stop’. gauge Stop’ and compare both read outs.
Touch key q
to clear display read out. Check key buttons for all add. machine operations.
Check calculator functions: Check positioning
50 : 2= 25 Touch key 0 ,Automatic Off’, and feed in the dimension
5x6= 30 100000.
100-l= 99 Touch the key m ,Automatic Start’ 2 times, the back-
100 + 1 = 101 gauge should automatically move to the dimension 100000
and stop.
3.11.12 Check keyboard for ,Add. Machine Operations’ Touch again key q
to turn off ,Numerical Keyboard’.
Touch each key on this keyboard and check whether each
pilot light of the buttons lits up.
POLAR-MOHR EMC
Kundf PrufDroqromm 115
customer testing ~rogromll5
Auftrag Nr: ;,u,r ?,:t ;i’: ProgrammNr’98 Mofieinfijgen
order no P program no : 98 recordmg of additional stop mark
I ET I m;:;Ure IX[D~;w@%- ~~1~, V I $ frx/x b -I- -I.&$ l)s...Y. 0

!
11x1
8 ,. j/ IIIIIII
Ilnnnn
z a"""" 1 / x x
2 Ijlsoo~
/ I
3 1 1 !O/O oo(0
fd I j I,919800/ &-.I_l_____-A ------- ! -
5 I /s/o o/o 0
/
6 / / IL19 8/O 0
7 / 1 /z/OOlO~~
8 / 1 /I 98iOb
9 / L o\o!o/ ------+ 9 Schnitte
9 cuts
lo j Jjj I
POLAR - hAnLID
wun n f-A AP
LzlVlL
Kunde Prufprcgramm 115
customer testlrq program115
Auftrq Nr; ;,u; P,“,,“,;’ 1L.f. Progromm Nr.: 1
order no P 1L.L program no.: 1 I
I PROGRAMMABLAUF
I ET/ 3:/ ,,",",",re 3 $ [y+?c;:)( b!-' - - & =b-.y. . SEQUENCE OF PRGGRAM 'B
V---- SchneLfen ypn Hand )
1X.1 50500; X X monu cu In!
7- ! I I ‘i7i717/7~7~
- - -1-j-
I IX X x
I II t
/ Taste bethtlgen
X ! x I x l!J Dress button i
X x I X
I
‘-f-,I “-I- , Ill
/I/l /I / IIX I I (
X I
I I I I / / , / I / I
61I / / , /-/
1 !SiLiOi&i / // /i // / i j 1 I I I I i /xl ;x1lq
x 2 u
Taste betatlgen
mess button
Taste oetotigen
+
7 / 15j3l0/0j0/ i i 1 / 1x 1 press button t
8 / 14 0 oloiI i / ’ X
I X X Schnelden van Hond
9 j !2/1 3oiol I manual cuttina i
, / I
10 / i j I I
Ncch dem Programmieren: After programming’ Nach Programmende:
betotlgen Anlageverstellung IundlI
l/_p 0 este
h ?\ auf l 2,5 steiien auf Nullsteilung bringen
f ‘t&J turnio+2 q
--After program end :
/ turn to-2.5 Turn backgauge com-
betctlgen
r,s opercte pensatlon Iand II to
betctlgen Saffei fohrt das erste Scnn!ttmafi on zero position
cperoi e Backi;auqe moves to the ftrst cutting measurement
Wezterer Ablauf siehe”P~ROGRAMMABLAUF”
6 Furtner operation see’SEQUENCE OF PROGRAM”
3.11.13
3.11.13 Test on full Memory Bank (Infeed to full capacity As the next step, touch key 0 ,Automatic Off’. Touch
of Memory) again key clx ,Program with cut and prepare erasing’ to
With key ? or ? bring display read out to number 98. turn off these functions.
Touch key tix ,Program with cut and prepare erasing’ also Touch key ..i*b ,Available cuts‘. In the readout display 7
key X erasing and key **Iv* for display of Available Cuts’, the number 0 (Zero) is visible and will change to ,512’
the readout display should show 512 after approx. 1 minute.
Touch key !’ and bring display to number 98 Touch key ? jvlemory Space Selector’, turn on ,Auto-
Record program matic Express’ $ and touch key q for ,Automatic Start’,
Touch keys 3 Automatic Express’ and ,Automatic Start‘. Backgauge will move to the first recorded setting.
Backgauge will move to starting position 115 cm Touch key u ,Automatic Knife Prepare’ and release first
Touch key r!j ,Automatic Knife’, the first cut has to be cut by hand.
released by hand. The memory bank will now receive au- This test also will require approx. 30 min.
tomatically the feed in of 5 12 stop recordings. This proce-
dure will require approx. 30 min.
3.11.13
Memory test of control panels with EPROMs dated 6th

July, 79
Bridge-over the two contact pins on the right side of the

plug-in Card N- KB.
On the same card bring the change-over switch mm/inch
in mm.
Adjust program No. 99.
Push erasing button.
It has been found to be advatageous to put all memory
places in position 0.
Push marking- button.
Program indication shows 98.
If all 512 places are occupied, take out the memory store
and put it back again. Hereby it is tested, that all data re-
main in the memory.
Test recall by actuating the marking-button.
The program indication starts to run with No. 1 and in
case of a fault in the memory it stops. If no fault exists,
the indicators runs up to 513.
It must be considered that during this test all datas previ-
ously recorded will be cancelled, equal to a total erasing.

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Das Polar-Service-Handbuch 3 gilt fiir alle POLAR EMC ab Baujahr

The Polar-Service-Manual 3 is valid for all POLAR EMC machines

INDEX OF SERVICE MANUAL POLAR 1151155 EMC

1.3 Hydraulic system

1.5 Machine testing and checkout

2.0 Description of functions

2.2 The Clutch

2.3 The machine hydraulics

2.4 TheClamp ................................................ 2.4

2.5 The Knife Carrier

2.6 The Table

Service manual 3 Service manual 2

2.7 Optical Cutting Line Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. , . . . 2.7

2.10 Measurement system

2.11 Summary of test works

3.0 Electrical Equipment

Service manual 3 Service manual 2

3.11 Survey of tests

1.1.20 Table Erection

2.0 Description of mechanical functions Machines of type 92,115 and 155

Relieve valve for safety pressure

Switching-control piston for clamp movement

Ball type and conical type valve solenoids:

Testing and check out procedure clutch pressure

Clamp pressure adjusting valve:

Testing and check out procedure clamp pressure:

Control slide piston

The pre-setting or adjustment of the clamp speed is done

2.6 Table Adjustment of the table brake

Check of the afterrun of the brake on machines with

By this system it is possible to test the afterrun of brake

Dismantling of the distance measuring system (from table)

It is important to secure the scanning head of the exchanged

in order to reduce wear on the dustcovers due to extreme

Beginning with machines of manufacturing year 1979 it

2.11 Check and test list 2.11.3 Adjustment-Correction of reference point

C E A = deadend bolt front

inch mm inch I mm inch mm inch

;1~c,/67 1385 A6653

155 29,s / 1,161 1 .---

Normally all POLARS are prepared for a 3 phase AC hook

electrical code for the hook up and it is therefore advise-

ov Control Voltage for Relay Coils

3.1.16 Adaption of Control Voltage to the Main Power

3.1.17.2 Card 2a Stabilized Voltage + 5 V To control the continuation of the - 6 V, an automatic

3.1.18.4 Plug-in Card 7SB: 1. Cut Release By Hand Or Automatic Knife:

Blue = ov ATTENTION: In case of a mechanical failure on one

Aften tion Analog-Digital

8V.w Reverse sigml

fed into, using the Bit Type System. I

3.1.30b Impulses of linear measuring scale

Current for signal “90°”

Reference point signal

Signal after imputsforming "0“'

I Signal after impulsforming” 90°”

Reference signal after impulsforming

1nnn Counted impulses multiplied .4x

3.1.3012 Connections on linear measuring scale

light emitter ph o toe/c mcnts

w= svt 7O~lo Signal O0 Signal 90° Reference signal Shielding