EMC2_gb2 03.05.

1998

Technical Training

for

EMC II

EM

SD - P

(Types 92, 115, 137, 155)

Imprint: File name: EMC2_gb2

First edition: 03.05.1998
Applicable for: Types SD, SD-P, EM, EMCII
Author: Harald Gutwald
Scope: 72 pages

Page 1
 EMC2_gb2 03.05.1998

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

Page 2
 EMC2_gb2 03.05.1998

Technical Data

Dimensions of POLAR models Backgauge speeds of POLAR machines

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

Deep: 175cm (68 1/8“) 152cm (59 1/8“) POLAR 76 EM forward fast 8,2 cm/sec.
Height: 140cm (55 1/8) forwrd slow 2,7 cm/sec.
Reverse fast 8,2 cm/sec.
POLAR 92 Width: 177cm (69 11/16“) with side tables
Deep: 211cm (79 1/8“) 212cm (83 1/2“)
Height: 147cm (57 1/8) POLAR 76 SD forward fast 8,2 cm/sec.
Reverse fast 8,2 cm/sec.
POLAR 115 Width: 177cm (69 11/16“) with side tables
Deep: 211cm (79 1/8“) 212cm (83 1/2“)
Height: 147cm (57 1/8) POLAR 92, 115, 137, 155 EM / EMC

POLAR 137 Width: 254cm (100“) with side tables forward fast 15,8 cm/sec.
Deep: 282cm (111 1/16“) 288cm (113 3/8“) forwrd slow 2,7 cm/sec.
Height: 165cm (64 15/16) Reverse fast 15,8 cm/sec.

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

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

POLAR 76 Weight complete: 1040 kg (2288 lbs)

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

POLAR 92 Weight complete: 1860 kg (4100 lbs)

Frame: 1162 kg (2556 lbs)
Table: 452 kg (994 lbs)
Floor load: 815 daN /m2
Spec. contact area load: 1,5 daN /m2
Dynamic surcharge: 20%

POLAR 115 Weight complete: 3240 kg (7128 lbs)

Frame: 2187 kg (4811 lbs)
Table: 994 kg (2186 lbs)
Floor load: 1100 daN /m2
Spec. contact area load: 1,6 daN /m2
Dynamic surcharge: 20%

POLAR 137 Weight complete: 4120 kg (9064 lbs)

Frame: 2465 kg (5423 lbs)
Table: 1355 kg (2981 lbs)
Floor load: 1150 daN /m2
Spec. contact area load: 2 daN /m2
Dynamic surcharge: 20%

POLAR 155 Weight complete: 4950 kg (10890 lbs)

Frame: 3350 kg (7370 lbs)
Table: 1580 kg (3476 lbs)
2m Table: 1830 kg (4026 lbs)
Floor load: 1150 daN /m2
Spec. contact area load: 2,4 daN /m2
Dynamic surcharge: 20%

* daN = kp

Page 3
 EMC2_gb2 03.05.1998

POWER MODULE
NOTE: TURN-OFF MACHINE (MAIN SWITCH) WHEN WORKING ON POWER MODULE!

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

Rough adaption Fine adaption

Mains with plug on main with Jumpers on
distributor fuse board

200 V 220 V 200 V

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

350 V 380 V 200 V

380 V 380 V 200 V
400 V 380 V 240 V
420 V 380 V 240 V
440 V 380 V 260 V
500 V* 380 V 220 V
600 V* 380 V 220 V

* requires step down transformer for control system.

All unused connector pins of voltage taps should be covered with the respective plastic caps.
If connections are changed re-insulate the unused pin with a cap.

Page 4
 EMC2_gb2 03.05.1998

Secondary AC voltages of the main transformer

SECONDARY USED FOR FUSE (PMF)

VOLTAGE (AC)

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

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

15V/30V FIXOMAT (special equipment)

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

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

12,5V Optical cutting-line indicator 2 x 4A slow (F3, F5)

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

Page 5
 EMC2_gb2 03.05.1998

The rectifiers for the secondary voltages 40V AC, 32 V AC and 11,5 V AC are on the heat sink in front of
the main transformer.

The board mounted on the heat sink contains the following items:

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

b) Rectifiers, smoothers and stabilisers for -12V DC, -30V DC, -12VB DC, and -30VB DC used
on EAROM Interface (EI) board and Interchangeable Data Storage (WSP).

Page 6
 EMC2_gb2 03.05.1998

STRUCTURE OF CONTROLS

The machine functions are controlled by three calculator boards.

1. MAIN COMPUTER (HR)

The main computer forms the head of the control system, thus directing all logical and arithmetical opera-
tions between the two sub-computers (positioning computer and keyboard computer). The data exchange
with the positioning computer is achieved via an I/0 port. The keyboard computer is connected through a
serial interface.

2. POSITIONING COMPUTER (AR)

The positioning computer (AR) controls the backgauge movements and cutting cycle. The respective posi-
tioning and cutting commands are given by the main computer. To control the motor logic (ML) and the
cutting circuit the static I/0 lines are connected from the board’s front side through the positioning compu-
ter interface (IAR) to the base plate.

3. KEYBOARD COMPUTER (BR)

The keyboard computer controls all the keys of the board for the operating unit (BT) and the board for the
special functions of the operating unit (BSF), resp. When a key has been actuated the keyboard computer
codes the information transmitting it to the main computer via a serial interface.

It is also via this serial interface that the main computer sends to the keyboard computer the commands
for indicating numerical values on the digital displays and for switching the LED’s ON/OFF.
These 3 plug-in boards are equipped with EPROM’s which store the data for the machine functions.

The storage expander board (SPE) is also equipped with EPROM’s. They contain the microprocessor pro-
gram. Furthermore, this board contains RAM’s for the data exchange between main computer and posi-
tioning computer.

On each EPROM of these 4 boards there is an adhesive label carrying a date or a program version.
The data or the program version, resp., marked on the labels must be the same for all 4 boards,
otherwise the cutter will not work.

The machine is permanently monitoring various functions and operating modes.

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

Page 7
 EMC2_gb2 03.05.1998

Description of Plug - In Boards

Test Point

24V
42V
0V
5V
•
•
•
•

Page 8
 EMC2_gb2 03.05.1998

POWER SUPPLY (PS 5 and PS 24)

The power supply boards are stabiliser circuits operating according to the principle of “pulse width
modulation”.

They furnish: a) + 5,1 V DC (PS5) to run the control logic except the keyboard computer

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

In order to serve as an input voltage of the power supply boards the secondary voltage of 32 V AC from
the main transformer is rectified and smoothened in the power module. The input voltage for board PS 5 is
decoupled by means of a diode and backed up by a 10,000 µF capacitor which supplies the energy
required for saving the current machine data when control voltage is turned off (data saving).

Moreover, the PS 5 board contains two voltage sensors which will initiate data saving after the control volt-
age has been turned off, and supply a reset pulse for main and positioning computer after switching the
voltage on. (Pin 9,10,11 +5V Reset Pulse - Pin 6, 8 Restart)

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

The output voltages of both boards are monitored by a green LED, each, and can be measured at the test
sockets at the front sides of the boards.

The output voltages are set to the following values by the factory:

PS 5: + 5,08 V - + 5,12 V
PS 24: + 23,9 V - + 24,1 V

The old typ of board can be re-adjusted, if necessary, by means of the potentiometer next to the
test sockets. The new types (see below) are not adjustable, if voltage is incorrect they must be replaced.

PS 24
PS 5

Page 9