EMC-Mon_op_GB_06.02.04

Mon op GB 01 06.02.2006

Technical Training

EMC MONITOR

Optional Equipment

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Accompanying material for technical training course

Mon op GB 01 06.02.2006

Table of Contents: EMC - Monitor OPTIONAL EQUIPMENT

Page Special function (SFM)............................................................................................................... 3 SFM board................................................................................................................................ 4 Pin assignment of special functions............................................................................................. 5 Arrangement of limit switches and valves on Autotrim.................................................................... 6 Optional Autotrim 80.................................................................................................................. 7 Pneumatic diagram of Autotrim.................................................................................................... 8 Autotrim Wiring Diagram........................................................................................................... 9 Manual lowering of front table (up to V 2.0) ................................................................................. 10 Manual lowering of front table (as of V 3.1) ................................................................................. 11 Autotrim parts list..................................................................................................................... 12 Special Hydraulic System (SHM)............................................................................................... 14 SHM board.............................................................................................................................. 15 Retractable side gauges on EM / EMC Monitor machines............................................................ 16 New plug-in board „Special Hydraulic System“ (SHM).................................................................. 17 Backgauge Lock on EM / EMC – Monitor machines.................................................................... 18 Circuit diagram of special hydraulic system Monitor..................................................................... 19 Special hydraulic system parts list............................................................................................. 20 Swivel / tilting backgauge / Fixomat (DNF) (SER)........................................................................ 22 DNF board............................................................................................................................... 23 Basic mechanical adjustment of swivel - tilting backgauge............................................................24 Adjustment of DNF board for swivel backgauge............................................................................25 Adjustment of DNF board for tilting backgauge............................................................................ 26 DNF block diagram................................................................................................................... 27 DNFparts list............................................................................................................................28 Servo control (optimized high-speed backgauge) .........................................................................29 Mains connection and block diagram of Servo control...................................................................30 Connections at ESR..................................................................................................................32 SERVO board.......................................................................................................................... 33 Setting instructions for servo board and servo amplifier................................................................. 34 Service information for servo drive unit......................................................................................... 36 Automatic clamping pressure regulation (PDR)............................................................................ 51 P1 Control unit for automatic clamping pressure regulation........................................................... 53 Functional principle of automatic clamping pressure regulation...................................................... 54 PDR setting instructions............................................................................................................55 Program (V2.0) for automatic clamping pressure regulation........................................................... 56 PDR plug-in board.................................................................................................................... 57 P1 – Oil Cycle with proportional pressure regulating valve............................................................. 58 PDR connecting plan............................................................................................................... 59

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Mon op GB 01 06.02.2006

Special function (SFM) The special functions board (SFM) serves to control the Autotrim table. In connection with the CP1 board the program cycle provides an automatic activation of the solenoid valves for the pneumatic cylinder of the front table. On machines without Autotrim facility, this function must be turned off via switch S1 on the SFM board. The board carries also eight relays which are energized for 0.5 seconds, each, when the external special functions 1 - 8 are executed. The potential free contacts of these relays allow to synchronize the peripheral equipments and the cutting sequence. The maximum tolerable load for the contacts is 10 watts, 48 V. Various inputs and outputs of the board allow for an adjustment of the control system to non-standard special versions.

LED V20 V1 V2 V3 V4 V5 V6 V7 V8 V9 P10 P11 V12

Color yellow red red red red red red red red red red red red

Meaning AT - LS monitoring Autotrim table CLOSE Autotrim table OPEN cut Automatic backgauge ON ext. special function No. 8 „ No. 7 „ No. 6 „ No. 5 „ No. 4 „ No. 3 Autotrim table LIFT No. 2 Autotrim table LOWER No. 1

Ground state OFF ON OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF

The special functions 1 -4 are carried out before the backgauge goes to the next position. The special functions 5 - 8 are performed when the size has been reached.

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Plug-in board SFM

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Pin assignment of special functions

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Mon op GB 01 06.02.2006

Arrangement of limit switches and valves on Autotrim

S 363 limit switch for bypassing the Autotrim light barrier S 364 limit switch Autotrim table closed S 365 limit switch Autotrim table open

Y 366 valve = table closed = Y 367 valve = table open = Y 389 valve = sweeper ON = Y 390 valve = lower table =

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Mon op GB 01 06.02.2006

Optional Autotrim 80 This optional equipment allows to handle waste cuts up to a max. 80 mm. In order to make this function possible, the mechanical construction of the Autotrim table must be widely reworked. The extended travel of the table, the blowing air device for removing cutting waste from the knife bar (stripper flap is dropped) and the movable right-hand side gauge have caused modifications to the pneumatic system and electrical control. The following components of the electrical control unit are required for Autotrim 80: 1. New SFM board id. no. 020172 ( replaces obsolete version 020171 ) 2. Suitable as of software versions V 6.1 - 0 V 5.3 - 0 V 4.4 - 0 The new SFM plug-in board ( 020172 ) can be used for all Autotrim machines. For this purpose, the board has DIP switches which allow the user to select between 25 mm and 80 mm for the waste cut. Switch position S 2 / 5 Switch position S 2 / 5

= OFF standard Autotrim ( 25 mm waste cut ) = ON = Autotrim 80 ( 80 mm waste cut )

The hardware of the new SFM board has been changed in the following way: when the opening process of the table was interrupted, and the table is then closed, both solenoid valves are briefly activated in order to fill the cylinders. This enables the Autotrim table to be started slowly and without jerks. The time period for activating the solenoid valves can be set on the board. Any unassigned inputs which were only available on the board, have been supplied to a 9-pin SUB D plug. The software modification of the CP1 board affects also the block program. Once Autotrim 80 is detected, any waste cut that may have been generated is set to 80 mm. New SFM, see IP 1 / 93

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Mon op GB 01 06.02.2006

Pneumatic diagram of Autotrim

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Autotrim Wiring Diagram

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Autotrim: Manual lowering of front table (up to V 2.0)

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Autotrim: Programmable lowering of front table (from V 3.1)

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Mon op GB 01 06.02.2006

Autotrim Parts List ( up to V 2.0 ) Component

Position

Function

M 371 N 380 Q 386 S 361 S 362 S 363 S 364 S 365 S 368 S 384 S 385

Table Frame Table Frame Frame Table Table Table Table Tiltable table Tiltable table

Compressor motor for suction and blown air Amplifier for light barrier, Autotrim Overload switch for compressor Button: Autotrim ( open ) in TR ( pushbutton board – right ) Button: Autotrim ( close ) in TR ( pushbutton board – right ) Amplifier for light barrier, Autotrim Limit switch Autotrim (close) Limit switch Autotrim (open) Changeover switch suction air – blown air Tilt table limit switch „left“ Tilt table limit switch „right“

S 386 S 388 SFM SER V 361 V 383 V 381 V 382 Y 94a Y 366 Y 367 Y 370 Y 389

Gearbox Table CU Switching board Frame Frame Frame Frame Table Table Table Table Table

Control switch for sweeper Button for sweeper „ON – OFF“ Plug-in board: Special function - Monitor special electrical system carrying the relay unit LED table ( open ) in TR Flashing diode for light barrier Autotrim Transmitter for light barrier Autotrim Receiver for light barrier Autotrim Solenoid valve „air supply ON / OFF“ Solenoid valve Autotrim (close) Solenoid valve Autotrim (open) Solenoid valve suction air Solenoid valve sweeper

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Mon op GB 01 06.02.2006

Autotrim Parts List ( from V 3.1 )

Component

Position

Function

K1 K2 K3 M 371 N 380 Q 386 S 361 S 362 S 363 S 364

TR TR TR Table Frame Table TR TR Table Table

Relay Lift the front table Relay Lower the front table Relay Change-over „blown air / suction air“ Compressor motor for blown air and suction air Amplifier for light barrier, Autotrim Overload switch for compressor Button Autotrim „open“ Button Autotrim „close“ Amplifier for light barrier, Autotrim Limit switch Autotrim (close)

S 365 S 384 S 385 S 386 S 388 S 400 S 401 SFM SER TR V2 V3 V 381 V 382 Y 94a Y 366 Y 367 Y 370 Y 389 Y 390

Table Tiltable table Tiltable table Gearbox Table TR TR CU Switching board Light barrier TR TR Frame Frame Table Table Table Table Table Table

Limit switch Autotrim (open) Tilt table limit switch „left“ Tilt table limit switch „right“ Control switch for sweeper „ON – OFF“ Button for sweeper „ON – OFF“ Button Autotrim Lift the front table Button Autotrim Lower the front table Plug-in board: Special function - Monitor special electrical system carrying the relay unit Pushbutton plate, right-hand Flashing diode for light barrier Autotrim LED Autotrim „open“ Transmitter for light barrier Autotrim Receiver for light barrier Autotrim Solenoid valve „air supply ON / OFF“ Solenoid valve Autotrim (close) Solenoid valve Autotrim (open) Solenoid valve Change-over „blown air - suction air“ Solenoid valve sweeper Solenoid valve Lower the front table

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Special Hydraulic System (SHM)

The hydraulic valves for the special equipment for

- Stack lifts - Retractable side gauges - Backgauge lock

are activated from the special hydraulic system board. The logic for interlocking the output signals is located on this board. In order to activate the functions „retractable side gauge“ and „backgauge lock“, the switches S1 and/or S2 must be turned to „1“. LED

Color

V8 V9 P10 P11 V12 V13 V14 V15

green green red red red red red red

V16

red

V17 V18

red red

+24 V +12 V Valve lift left-hand side Y 160 Hy switch Y 330 Valve lift right-hand side Y 158 Valve VL left-hand side Y 155a Valve VL right-hand side Y 155b Valve - backgauge lock fixed Y 331 Valve - backgauge lock clear Y 391 Spare Spare

Meaning Ground state

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ON ON OFF OFF OFF OFF OFF OFF OFF OFF OFF


Mon op GB 01 06.02.2006

Special Hydraulic System (SHM) Plug-in Board

VL = retractable side gauge

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Retractable side gauges on EM / EMC Monitor machines

In the Monitor machine range, the 176 model was the first to introduce a new design of the hydraulically retractable side gauges. Both directions of motion (up / down) are now controlled hydraulically. The relevant limit positions are scanned via limit switches. On this version, the hydraulic pressure is turned off when the gauges are lowered. Besides the mechanical and hydraulic modifications this new model requires a new special hydraulics plug-in board. The new board SHM 020182 replaces the previous version with id. no. 020181. Before using this board with the older VL version, the switches and jumpers on the board need to be set correctly. There are three different variants: 1. Machines 115 to 155 ( Programs V 1.0 - V 6.0 ) Version with unidirectional hydraulically controlled VL cylinder. Return motion (VL up) by spring power. The VL is retained in its bottom position by a constantly activated special hydraulic system. When employing the new SHM board ( 020182 ) the following setting needs to be made:

1. Switch S 1 2. Switch S 2 3. Switch S 3 4. Switch S 4 5. Jumper JP 1 6. Jumper JP 2 7. Jumper JP 3

ON = VL available ON = backgauge lock ON ON = old VL version ON = Cut optimization (must be turned on) ON ON ON ( Pin 1+2 )

2. 176 Machines VL control in both directions through hydraulic system (twin cylinder). 1. Switch S 1 2. Switch S 2 3. Switch S 3 4. Switch S 4 5. Jumper JP 1 6. Jumper JP 2 7. Jumper JP 3

ON = VL available ON = backgauge lock ON (176 = OFF) ON = old VL version ON = Cut optimization (must be turned on) OFF OFF ON ( Pins 2+3 )

3. Machines 115 to 155 ( retrofit kit with program V 6.1 ) Version with unidirectional hydraulically controlled VL cylinder. Return motion (VL up) by spring power. By converting the hydraulic / electrical system, the VL can also be retained in its bottom position without any hydraulic pressure. This prevents excessive heating of the hydraulic system. The setting of switches and jumpers on the SHM board is the same as on the 176 MON machine.

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Mon op GB 01 06.02.2006

Switches and jumper positions on the new SHM board

old VL with recovery spring

The function of the key vor > lower both VL < in the left-hand light barrier housing, can be preselected by removing or inserting the diode V 7 on the new SHM board. If the diode is available, both VL are activated by pressing the key „lower both VL“. If there is no diode, only the right-hand VL will be activated. The operation of the left-hand VL remains unchanged.

see IP 1 / 93

VL neu Mit doppel Zylinder

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Mon op GB 01 06.02.2006

Backgauge Lock on EM / EMC – Monitor machines Description of functions: The following solenoid valves are required for the backgauge lock function: Y330 change-over valve (switch) Y331 needle valve tap (clamping ON) Y391 needle valve tap (clamping OFF) On all the machines equipped with backgauge lock this function must be turned on with switch S 2 on the SHM board. The functioning of individual valves is indicated by LEDs on the SHM board. (see SHM board). When the machine is turned on, no solenoid valve of the backgauge lock is activated, but through a spring storage element which is integrated into the backgauge lock control unit, the backgauge lock remains activated even when the machine is switched off. With the backgauge at rest, the spring storage element also ensures that the pressure in the hydraulic circuit of the backgauge lock will be maintained even when the solenoid valves Y 330 and Y 331 are no longer energized. With a volume of approx. 3 cm³ the spring storage element is sufficient to compensate any arising pressure loss. By activating the motor brake of the backgauge drive motor, the solenoid valve Y 391 is briefly turned on and provides a direct connection with the hydraulic tank. The oil contained in the backgauge lock control circuit flows off and the backgauge lock is relieved. When the backgauge stops, simultaneously with the shutoff of the motor brake the change-over valve Y 330 and the needle valve tap Y 331 are briefly turned on by the CP 1 computer via the SHM board. In this way the oil circuit of the special hydraulic system is connected with pump P2 through the changeover valve, while the needle valve tap opens the line to the clamping cylinder at the sledge. The backgauge lock function is automatically carried out by CP1 provided that switch S 2 on the SHM board is set to „1“. If the backgauge lock function is turned off by switch S 2 on the SHM board, Y391 will be shortly activated to relieve the backgauge lock.

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Circuit diagram of special hydraulic system

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Parts list no. 1 - Special hydraulic system Component CP 1 CU LG PS SHM TL TR S 156a S 156b S 156c S 161a S 161b S 162a S 162b S 171 S 173 SHM. K1 SHM. K2 SHM. K3 SHM. K4 SHM. -K5 SHM. K6 SHM. K7 SHM. K8 SHM. K9 SHM. K10 SHM. K11 SHM. S1 SHM. S2 SHM. V8 SHM. V9 SHM. P10 SHM. P11 SHM. V12 SHM. V13 SHM. V14 SHM. V15 SHM. V16 SHM. V17 SHM. V18 SHM. V19 SHM. V20

Position CU Frame CU CU CU Frame Frame TL TL TL TR TR TL TL Lift Lift SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM SHM

Function Plug-in board: Central Processor Control unit motherboard Air cup – distributor board Plug-in board: Power Supply + 5V / 12V / 24 V = Plug-in board: Special hydraulic system Pushbutton board left-hand side Pushbutton plate right-hand side Key: Retractable side gauge, left-hand down Key: Retractable side gauge, left and right-hand down Key: Retractable side gauge, upper position Key: Stack lift, right-hand side, up Key: Stack lift, right-hand side, down Key: Stack lift, left-hand side, up Key: Stack lift, left-hand side, down Air cup: left-hand limit switch Air cup: right-hand limit switch Relay: solenoid valve – lift left-hand side up Relay: solenoid valve backgauge lock fixed Relay: solenoid valve - spare Relay: solenoid valve - retractable side gauge, right-hand Relay: Spare Relay: solenoid valve - retractable side gauge, left-hand Relay: Spare Relay: solenoid valve – lift right-hand side up Relay: Spare Relay: change-over valve ON Relay: solenoid valve backgauge lock relieved Changeover switch: Retractable gauge available / not available Changeover switch: backgauge lock activated / not activated Indication: Control voltage +12 V d.c. Indication: Control voltage +24V d.c. Indication: solenoid valve – lift left-hand side ON Indication: change-over valve (switch) ON Indication: Lift, right-hand side ON Indication: Retractable side gauge, left-hand ON Indication: Retractable side gauge, right-hand ON Indication: backgauge lock fixed Indication: backgauge lock relieved Indication: Spare Indication: Spare Indication: Spare Indication: Spare

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Mon op GB 01 06.02.2006

Parts list no. 1 - Special hydraulic system Component TL. V3 TL. V5 Y 155a Y 155b Y 158 Y 160 Y 170 Y 172 Y 330 Y 331 Y 391

Position TL TL Frame Frame Frame Frame Blower Blower Frame Frame Frame

Function Indication: Retractable side gauge, left-hand lowered Indication: Retractable side gauge, both lowered Solenoid valve: Retractable side gauge, left-hand down Solenoid valve: Retractable side gauge, right-hand down Solenoid valve: Stack lift, right-hand side, up Solenoid valve: Stack lift, left-hand side, up Solenoid valve: air for air cap left-hand side Solenoid valve: air for air cap right-hand side change-over valve (switch) Solenoid valve: backgauge lock fixed Solenoid valve: backgauge lock relieved

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Swivel / tilting backgauge / Fixomat (DNF) (SER) The DNF board controls the d. c. motors of the Fixomat front and side lay marks. The supply voltage of the motors is derived from the secondary voltage 0 - 15 - 30 Va.c. of the control transformer. The three-phase motors for the swivel and tilting backgauge are activated through the relays K 353 - K 354 - K 355 - K 356 on the SER board. Potentiometers acknowledge the current status of the backgauge setting. The analog voltages of the potentiometers are digitized on board DNF via an analog-digital converter and then signaled to the central processor (CP 1). Depending on the machine equipment, the different functions need to be activated by the switches on the DNF board. S 1 for tilting backgauge

S 2 for swivel backgauge

S 3 for Fixomat

LED V1

Color yellow

Meaning Tilting backgauge activated

Ground state on / off

V2

yellow

Swivel backgauge 0 position

S 352

on

V3

yellow

Tilting backgauge 0 position

S 351

on

V4

red

)

V5

red

)

V6

red

) indication for the position

V7

red

) Swivel / tilting backgauge

V8

red

)

V9

red

)

V 10

yellow

Fixomat side lay mark

S 341

on

resting position V 11

yellow

Fixomat side lay mark activated

S 342

off

V 12

yellow

Fixomat front lay mark

S 343

on

S 344

off

resting position V 13

yellow

Fixomat side lay mark activated

V 14

red

Fixomat side lay mark, swivel forward

off

V 15

red

Fixomat swivel back the side lay mark

off

V 16

red

Fixomat front lay mark swivel forward

off

V 17

red

Fixomat swivel back the side lay mark

off

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DNF plug-in board

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Basic mechanical adjustment = swivel backgauge =

Basic mechanical adjustment = tilting backgauge =

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Adjustment of board DNF for swivel and tilting backgauges Swivel backgauge setting: Select swivel backgauge! 1.) Move swivel backgauge mechanically to zero position ( see page 24 ). 2.) Adjust potentiometer RD in such a way that a voltage of 2.5 V +/- 0.05 V can be measured between the measuring points MP1 and MP5. 3.) Use potentiometer R41 to set the voltage between the measuring points MP1 and MP4 to 0 V +/- 2 mV. 4.) Turn the center switching cam at the backgauge, until switch S352 is actuated. LED V2 is on. 5.) Set the swivel backgauge to maximum mechanical displacement, using the controls - swivel backgauge right-hand side forward. (Before doing so, attach the dial gauge to the front edge of the rake. ) Swivel backgauge, right-hand (displacement at outside rake) POLAR 115 1.3 mm POLAR 137 1.5 mm POLAR 155 1.7 mm

6.) Turn the switching cam, until delimiting switch S348 is actuated. 7.) Use potentiometer R39 (DNF) to set the following LED indications: V4 V5 V6 V7 V8 V9

OFF OFF ON ON OFF OFF

This setting is equivalent with the value 20 in the indication with swivel backgauge right-hand side forward!

8.) Set the swivel backgauge to maximum mechanical displacement, using the controls - swivel backgauge left-hand side forward. (Before doing so, attach the dial gauge to the front edge of the rake. ) Swivel backgauge left-hand side (displacement at outside rake) POLAR 115 1.3 mm POLAR 137 1.5 mm POLAR 155 1.7 mm

9.) Turn the switching cam, until delimiting switch S347 is actuated. After the setting is finished the monitor must display the following values for the final position: swivel backgauge left + right-hand side = 20

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Adjustment of board DNF for swivel and tilting backgauges = Tilting backgauge setting = Select tilting backgauge! 1.) Move tilting backgauge mechanically to zero position ( see page 24 ). 2.) Adjust potentiometer RN in such a way that a voltage of 2.9 V +/- 0.05 V can be measured between the measuring points MP3 and MP5. 3.) Use potentiometer R44 to set the voltage between the measuring points MP3 and MP4 to 0 V +/- 2 mV. 4.) Turn the center switching cam at the backgauge, until switch S351 is actuated. LED V3 is on. 5.) Set the tilting backgauge to maximum mechanical displacement, using the controls - tilting backgauge backward. (Before doing so, attach the dial gauge to the front edge of the rake. ) Tilting backgauge „backward“ ( Displacement at upper edge of rake ) 1.7 mm 1.7 mm 1.7 mm

6.) Turn the switching cam, until delimiting switch S350 is actuated. 7.) Use potentiometer R42 (DNF) to set the following LED indications: V4 V5 V6 V7 V8 V9

OFF OFF ON ON OFF OFF

This setting is equivalent with the value 20 in the display only with tilting backgauge „backward“!

8.) Set the tilting backgauge to maximum mechanical displacement, using the controls - tilting backgauge forward. (Before doing so, attach the dial gauge to the front edge of the rake. ) Tilting backgauge „forward“ ( Displacement at upper edge of rake ) 0.5 mm 0.5 mm 0.5 mm 9.) Turn the switching cam, until delimiting switch S349 is actuated. After the setting is finished the monitor must display the following values for the final position: tilting backgauge backward = 20

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tilting backgauge forward = 7


Mon op GB 01 06.02.2006

Detailed wiring diagram DNF

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Parts List D N F Component BIM BT-DNF CP 1 CU DNF KC PM SER S 341 S 342 M 345 S 343 S 344 M 346

Position Frame Frame CU Frame Frame Frame Frame Frame Backgauge Backgauge Backgauge Backgauge Backgauge Backgauge

Function Control panel Fixomat, swivel and tilting backgauge control unit Plug-in board: Central Processor Control unit motherboard Swivel backgauge, tilting backgauge and Fixomat control unit Keyboard Computer Power supply unit Special electrical system carrying the relay unit Limit switch: retracted, side lay mark Limit switch: extended, side lay mark Motor: Fixomat for side lay mark Limit switch: retracted, front lay mark Limit switch: extended, front lay mark Motor: Fixomat for front lay mark Swivel backgauge

S 347 S 352 S 348 RD M 357 K 353 K 354

Backgauge Backgauge Backgauge Backgauge Backgauge SER SER

Limit switch: backgauge, left-hand Limit switch: 0 position Limit switch: backgauge, right-hand Potentiometer: Acknowledgement Motor for swivel backgauge Relay: backgauge, left-hand Relay: backgauge, right-hand Tilting backgauge

S 349 S 351 S 350 RN M 358 K 355 K 356 V 10 V 11 V 12 V 13 V 14 V 15 V 16 V 17

Backgauge Backgauge Backgauge Backgauge Backgauge SER SER FIX FIX FIX FIX FIX FIX FIX FIX

Limit switch: Backgauge at front Limit switch: 0 position Limit switch: Backgauge at rear Potentiometer: Acknowledgement Motor for tilting backgauge Relay: Backgauge at front Relay: Backgauge at rear Limit switch S 341 actuated (end position side lay mark, rear) Limit switch S 342 actuated (end position side lay mark, front) Limit switch S 343 actuated (end position front lay mark, rear) Limit switch S 344 actuated (end position front lay mark, front) Motor control M 345 (retract side lay mark) Motor control M 345 (extend side lay mark) Motor control M 346 (retract front lay mark) Motor control M 346 (extend front lay mark)

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Servo control (optimized high-speed backgauge) Mechanical system: ball-bearing spindle ball bushing bearing housing (rear) spindle bearing block (front) backgauge sledge (bigger bore hole) motor pinion spindle pinion toothed belt motor console *

Electrical system: Servo motor 120Vd.c. (Bautz) power amplifier (ESR) Servo plug-in board (Servo) CP 1 computer board(V... S) rear limit switch S 13a (Ö) * front limit switch S 7 / S 8 (Ö) *

In automatic operation the limit switches change over the backgauge speed to „slow“. ( = a quarter of the maximum speed ) On special versions (Transomat 3 BL, gripper transport system) the S121 switch is used instead of limit switch S 13a.

Description of functions

Mechanical system: The ball bearing spindle with ball bushing is set during the assembly in the factory. It requires no readjustment even after a longer operation time. the ball bearing spindle always has to be replaced completely, together with the ball bushing. Never turn the ball bushing off the spindle, because all the balls would drop out of the bushing and the bushing could not be used any longer. A mounting sleeve is necessary for installing the ball bushing onto the spindle and also for dismantling it. In dismantled condition, the spindle torque should be 1 Nm. In assembled condition a value of 2.5 Nm should not be exceeded.

Electrical system: The ESR Servo power amplifier is mounted to the crosshead under the rear table. The mains connection is made from the machine with a 5-core cable via adapter plug no. 100. The supply voltage can be changed over in the power amplifier from 200 - 440 V three-phase.

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Power supply from control unit

The servo motor is connected with a shielded two-core cable from the power amplifier’s terminals 1 and 2, shielding terminal 3. The tachometer generator is also connected by a shielded 2-core cable at the power amplifier, terminals 4 and 5, shielding terminal 3. As on the machines without servo control, the motor brake is connected with a two-core cable, plug 104, at the MCM. Data transfer from the Servo board to the Servo power amplifier is performed with a four-core cable with 15pin plug.

Servo Control block diagram

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Mon op GB 01 06.02.2006

Explanations regarding the block diagram on page 30

(( 1* ) =Enable: Signal „Motor ON“. For backgauge movement, the enable signal is issued from CP 1 via yP bus to PI. PI signals „brake enabled“ and the K1 relay on PI turns on the K1 relay on the Servo board. Zero signal is indicated on terminal 15 of the control unit and power amplifier is activated. Servo LED V9 = brake enabled / V1 = motor ON. ( 2.) = Control signal: Control voltage for motor speed control. Depending on the machine direction there is a voltage between 0 and + 10V d. c. or 0 and - 10V d. c. 0V with „backgauge Stop“. The control signal is supplied from the CP 1 via the yP bus and the „Servo“ board to the control unit (ESR). Terminal 11 Through voltage control the motor speed is infinitely variable from V 0 to V max. The motor brake is switched on when the CP 1 has the signal V 0. The brake is meant to lock the motor at standstill. The V max. speed (approx. 31 cm./sec.) is reached after approx. 13.5 cm, and in automatic mode, only. The regulation from V max. to V 0 requires also 13.5 cm. In the service display this value is indicated as a slow down travel. The V max. speed is only obtained with distances of more than 27 cm. The max. current of the control unit is set to 12 amps. If the current limit is set too low, the motor will not reach its full speed. At V max. the current is about 5.5 amps. The motor speed is determined with a tachometer generator. When the speedometer fails, the backgauge will go to V max. manually and without control. Poor carbon brushes will cause uneven operation! Drift velocity. This velocity is only determined in a reference run. Once the rear table limit switch (S13) has been reached, the backgauge stops its advance movement for approx. 2 – 3 sec. after about 15 cm. The power glide is measured and the backgauge moves forward to approx. 40 cm. The drift depends on the offset adjustment on the Servo board as well as the zero point in the ESR amplifier. Set the current limit. As of CP 1 version V 6.0 the error message „No pulses from measuring system“ is issued when the backgauge is locked. From this program version, the auxiliary operation must be turned on before the current limit can be set. When the carbon brushes of the tachometer generator are worn or soiled, the motor will not run smoothly or it will approach the positions inaccurately. Carbon brushes for motor : Id. no. 227361 4 x

Carbon brushes for tachometer generator: Id. no. 227362 2 x

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Mon op GB 01 06.02.2006

The ESR has the following connections:

Terminal 11 = orange Terminal 13 = yellow Terminal 14 = brown Terminal 15 = red Terminal 20 = all black-colored cores

up to max. + 10 V depending on direction of rotation - 14 V + 14 V Enable (relay K1 on Servo board) 0V

The table limit switches S 13a ( S121 ) and S 7 are connected to the Servo board by means of the 9pin plug. The Servo power amplifier has three light-emitting diodes which indicate different operational conditions.

Operation Limit switch opened Enabling actuated Overload indication

x green x yellow

(all voltages available) during operation: „OFF“

x red Beneath the LEDs there are five trimming potentiometers (rotation top the right means)

current setting feedback adjustment I x R compensation without tachometer generator) Zero point adjustment Speed setting

P4 P3 P8

(current is increased) (motor runs more smoothly) ( stronger compensation, only used

P2 P1

( motor standstill ) (speed is increased)

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Mon op GB 01 06.02.2006

Servo plug-in board

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Mon op GB 01 06.02.2006

SERVO SETTING ! Move backgauge to center of table! 1. Zero balancing of Servo board in CUM module The Servo board must be plugged onto an adapter. Make sure that the computer has preset a control voltage of 0 V (automatic positioning must not be activated). Connect voltmeter to measuring points MP 2 and J2 Pin 3. Use potentiometer P1 to set the voltage to 0 V. Switch the machine off and remove the adapter board.

2. Zero balancing of Servo power amplifier ESR a) Jumper J2 on the Servo board in such a away that the Pins 2 and 3 are linked. b) Connect terminals 15 and 20 on the power amplifier with a jumper ( enable ). c) By-pass the S 18 switch of the manual precision adjustment at plug CUM 14, contacts 3 and 6, ( Motor brake must be activated ). Then, switch the machine on. d) Adjust potentiometer P2 at the ESR ( zero point adjustment ) until servo motor is at a standstill ( see „actual value“ on the monitor or measure the speedometer voltage). Switch machine off . e) Plug jumper J2 on Servo board in such a away that the Pins 1 and 2 are linked. Remove bridges between terminals 15 and 20 as well as switch S18 at CUM 14.6 and CUM 14.3.

3. Setting the number of revolutions at the servo power amplifier (ESR) With the tachometer the number of revolutions is measured direct at the end of the spindle (second person necessary). The potentiometer P1 ( speed ) is adjusted in such a way that the spindle runs 1800 rpm. in automatic operation, and 900 rpm. in manual operation (use hand wheel). The motor speed must not exceed 2800 rpm. (measured at the motor shaft).

4. Feedback setting procedure The feedback is set at P3 ( feedback ) in the following way: Turn the potentiometer P3 counterclockwise, until the servo motor runs audibly harsh. Then turn the potentiometer P3 slowly clockwise, until the servo motor runs smoothly over the entire speed range. Then check movement to position without display correction.

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Mon op GB 01 06.02.2006

5. Setting the power limit The current setting at the servo power amplifier is carried out in the factory. It should only be readjusted when the P4 potentiometer (current setting) has been misadjusted or the red LED lights up because of an excessive load on the servomotor. The current can be set from 2 – 12 amps. Lock the motor (best at the rear of the table). Switch measuring instrument into motor line. (direct current up to 30 amps) Set current at P4 to max. 12 amps. Note: From CP1 version V 6.0 the auxiliary operation must be activated before the current limit can be set. Otherwise, when the backgauge is locked the error message „No pulses from measuring system“ would be issued. After any new setting the machine must be initialized in a reference run, because the new machine parameters on the CP4 board must be saved as machine data!

The servo board has six LEDs. V1

= yellow

Enabling of servo control; in operation „ON“

V2

= red

not assigned

V3

= green

not assigned

V9

= yellow

Motor brake active

V 10 = yellow

table limit switch S 13a (S 121)

V 11 = yellow

table limit switch S 7

Technical Data:

Accuracy allowance

= 0.008 cm - 0.100 cm adjustable

Slow down travel

= approx. 13.000 cm

Brake afterrun

= 0 – 0.004 cm

Drift (as of CP 1 V 6.0)

= cm / sec. ( 0, if possible )

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Mon op GB 01 06.02.2006

SERVICE INFORMATION Optimized high-speed backgauge (servo drive) 1. Servo boards The following boards have been employed for servo machines by now Id. no. 023184 used up to program version V 6.1/A-Z/O, incl. Id. no. 029176 used from program version V 6.2 - 0 Id. no. 029216 used only with model EMC - G (full graphics) Information regarding servo board id. no. 029176 This board helps to get a more distinct information from the error message „No pulses from measuring system“. There is a hint regarding a defective servo amplifier and backgauge motor. This distinction can only be made provided that program version as of V 6.1 and the new set of cables ( id. no. 029346 and 029348 ) are installed. On machines with 2-m table the cable set (id. no. 029346 and 029347) is indispensable. 2. CP 1 computer board The following program statuses have been employed for servo machines so far: CP 1 V 3.0 S CP 1 V 3.1 S CP 1 V 4.0 S CP 1 V 4.1 S CP 1 V 4.2 S CP 1 V 4.3 S CP 1 V 4.4

Id. no. 020153 Id. no. 020157 Id. no. 023804 Id. no. 023611 Id. no. 023612 Id. no. 023613 Id. no. 023774

CP 1 V 5.0 S CP 1 V 5.1 S CP 1 V 6.0 S CP 1 V 6.1-0 a CP 1 V 6.1-0 b CP 1 V 6.1-0 c CP 1 V 6.1-0 d CP 1 V 6.1-0 e CP 1 V 6.2-0

Id. no. 024340 Id. no. 024341 Id. no. 024850 Id. no. Id. no. Id. no. Id. no. Id. no. Id. no. 024841

no longer available no longer available machines without PMS keyboard computer id no. 020111

„S“ identification is omitted, because program is also designed for normal drive machines with PMS keyboard computer id no. 023831 machines with PMS keyboard computer id no. 023832

„S“ identification is omitted, because program is also designed for normal drive replaces all programs from V 6.1 / A - Z / 0

3. Cable harness: Servo board / servo amplifier Old version, consisting of two cables with New version, consisting of two cables with {new version of cables for 2-m table with)

Id. no. 023173 and 023174 Id. no. 029346 and 029348 Id. no. 029346 and 029347

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Mon op GB 01 06.02.2006

4. Servo amplifier ESR The following devices have been used by now: a.) BN 6454. 0715 b.) BN 6454. 0890 c.) BN 6454. 0950

id. no. 227014 id. no. 227153 id. no. 227153

prim. Connection prim. Connection prim. Connection

3 x 380V 3 x 200V to 3 x 415V 3 x 200V to 3 x 440V

The following PI wiring was selected for the above mentioned units: The wiring applies to the program versions V 3.0 S to V 5.1 S 1. 2.

r 37 = 52 k Ohm c13 = 100 nF

d.) BN 6454. 1222

id. no. 228925

prim. Connection

3 x 200V to 3 x 440V

The following PI wiring was selected for the above mentioned units: The wiring applies to the program version V 6.0 S 1. 2.

r 37 = 100 k Ohm c13 = 33 nF

e.) BN 6454. 1439 id. no. 229229 prim. connection 3 x 200V to 3 x 440V The following PI wiring was selected for the above mentioned unit: The wiring applies to program versions as of V 6.1 - 0 1. 2.

r 37 = 110 k Ohm c13 = 15 nF The BN 6454.1439 device is equipped with a DIP switch which makes it easy to make the PI adjustment when the device has to be replaced, (see section on PI wiring)

Some of the devices designated as assembly 1222 and 1439 are designed short-circuit proof. You can recognize this feature by a red-colored LED on the base plate of the amplifier. All those defective servo amplifiers sent-in for repair which do not comply with the technical status of the BN 6454.1439 device will be modified correspondingly. This means that all replaced devices which have been given the new type number 1439 after their conversion, will provide the same configurations which the new devices provide.

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Mon op GB 01 06.02.2006

5. PI wiring at servo amplifier ( PI = proportional / integral ) The setting for the relevant program status is made with switches S1 to S6. For the current delivery status of the ESR device, please refer to the table.

LED 1 = operation LED 2 = limit switch LED 3 = overload

P 4 Potentiometer = current limit P 3 Potentiometer = feedback P 8 Potentiometer = I / R compensation P 2 Potentiometer = zero point P 1 Potentiometer = number of revolutions

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Mon op GB 01 06.02.2006

Examples for replacing a servo amplifier: Machine 155 EMC - Monitor, S No: 5821123, Program status V 3.1 S 1. If the complete servo amplifier of the mentioned machine was defective and has to be replaced, only the DIP switches for PI adjustment need to be fine-tuned . The switch package at amplifier 1439 becomes visible after the plug-in module at the ESR device has been removed. (see drawing on page 39) Before putting the machine into service, the motor should also be inspected. (Please observe the maintenance of the motor). 2.

Same condition as in item 1, but conversion to new software V 6.1 / A - Z / V 6.2-0 a. New servo amplifier BN 6454. 1439 b. New servoboard id. no. 029176 c. New cable harness id. no. 029346 + 029348 / 029347 d. New CP 1 board id. no. 024841 (V 6.2 - 0) e. New keyboard computer id no. 023832

These service parts are required for the complete conversion. After the parts have been assembled, the servo drive unit must be re-calibrated (see setting instructions for servo drive unit)

Servo amplifier with optional leakage protection equipment This optional equipment has been integrated into new devices from the model BN 6454.1222 onwards. It can be recognized from the red LED on the amplifier base plate. In normal operation the LED is off. When the LED lights up, the motor and supply line must be checked for accidental ground.

Plug-in module BN 37.1439

Output stages and controller board can be ordered under id. no. 229367 from our spare parts department. In case of a defect in an output stage, you always have to replace both modules. The assembly, id. no. 229367 is suitable for all the servo amplifiers delivered so far.

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Mon op GB 01 06.02.2006

block diagram of servo drive unit forward movement of backgauge via hand wheel (button S 10) 1. input signal to Pl board (LED V23) 2. information supplied via uP bus to CP 1 3. CP 1 controls PI board via uP bus a: brake Y17 (LED V33) b: K1 on Pl (+24V via n/o contact LED V9) 4. CP 1 controls servo board via uP bus a: K1 on servo board (NC contact), =enabling of servo amplifier= b: control signal for ESR device (approx. 4.8Vd. c.)

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Mon op GB 01 06.02.2006

Wiring diagram SERVO drive unit

Control signal: Control voltage for motor speed control. Depending on the direction of rotation and number of revolutions there is a voltage between 0 and + or - 10V d. c., respectively. The control signal is supplied from the CP 1 through the yP bus via the „Servo“ board to the control unit (ESR) terminal 11. Enable: Control signal „MOTOR ON“. For backgauge movement, the enable signal is issued from CP 1 via yP bus to board PI. The PI board responds with the signal „brake Y17 electrically activated“ and simultaneously turns on the K1 relay on the servo board with its relay K1. Zero signal is indicated on terminal 15 of the control unit and the power amplifier is activated. Servo LED : V 9 ON = brake electrically activated / V1 ON = Motor on. Acknowledgement: Voltage level for CP 1 board for information about current motor speed. Depending on the number of revolutions and direction of rotation there is a voltage between 0 and + or –14 V, respectively.

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Mon op GB 01 06.02.2006

Problem solving for machines with servo drive Description of fault:

Zero point and drift cannot be adjusted correctly, or zero point or drift are not stable while machine is in operation. Optimal value for zero point or drift is the value >0.000<. with the resulting brake afterrun, which is also >0.000< with optimal zero point or drift. Major variations between positive and negative values of drift and brake afterrun also indicate that there must be an error in the adjustment. admissible tolerances for Drift: Brake afterrun:

- 0.002 cm / sec to + 0.002 cm / sec 0.000cm to 0.004 cm maximum

Mechanical check: Make sure that there is no mechanical stiffness throughout the backgauge travel. First, remove the toothed belt from the spindle drive unit. Then slowly move the backgauge over the entire travel, using a torque wrench. The max. admissible torque of 2.5 Nm must not be exceeded in this case. If the value is higher on some points, please check the spindle guides, spindle and backgauge support for damages. The permissible torque of the spindle alone (friction value spindle / nut) must not exceed 1 Nm. Moreover, after activation of the motor brake an unimpeded rotation of the motor must be possible. This can be ensured by supplying the brake coil directly with + 24 V d.c. If you notice a partial mechanical stiffness, please re-adjust the brake or replace it. Inspection of the motor control system: As far as the servocontrol system is concerned, all the conversion steps should be taken to obtain the status BN 6454.1439. This includes modifying the servo board and the amplifier cable. The following measure should be performed: 1.

At the servo amplifier, please remove the bridge between the two terminals no. 12 and no. 20.

3.

The amplifier (ESR) has a jumper on the base plate which must be removed.

3.

Attach jumpers on the servo board.

4.

Modify connection cable of servo amplifier. ( please observe the drawings on pages 47 and 48 when carrying out the conversion)

If an additional error differentiation in the display shall be obtained, upgrade the program to version V 6.1 – 0 or higher, and install the new cable harness which has two additional cores. The new servo board id. no. 029176 is also required.

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Mon op GB 01 06.02.2006

Maintenance and repair of the servo motor with holding brake The d. c. motor (made by Bautz) employed for driving the ball bearing spindle is composed of three assemblies: 1. D. c. motor 1. D. c. motor

2. Tachometer generator

3. Holding brake

( carbon brushes 4 x id. no. 227361 )

The maximum voltage allowed to be supplied to the motor is 120V d. c.. The motor is supplied from the ESR amplifier (terminals 1+2) via carbon brushes onto the collector. The max. adjusted voltage in this example is approx. 112 V d.c. at a motor speed of approx. 2,800 rpm. Important! The new carbon brushes are 17 mm long, and must never be shorter than 5 mm. Besides, please make sure that the carbon brushes show an even contact pattern. Since the carbon brushes are abrading and this powdered carbon collects in the motor and at the collector, the motor must be sent-in to the manufacturer for maintenance work after the carbon brushes have been changed for the third time. The motor cannot be cleaned on site, because the relevant cleaning devices (such as ultrasonic cleaning) are not available. Furthermore, when the motor is at the manufacturer’s for maintenance purposes, the bearing will be replaced and the collector re-worked. If the motor is not serviced, the deposit of carbon dust may cause an accidental ground in the motor which results in malfunctions, or may even cause the servo amplifier to be damaged in individual cases. Since the applications of the cutting machines vary greatly it is not possible to indicate a definite period for the change of the carbon brushes. The motor should also be inspected with regard to accidental ground, before new brushes are installed or if there are temporary malfunctions of the servo drive. In that case disconnect the motor, check both lines for connection against the motor housing with an ohmmeter; the collector should also been turned for this purpose). 2. Tachometer generator

( carbon brushes 2 x id. no. 227362 )

The tachometer generator is connected with the motor shaft and generates a voltage during the motor run, which is supplied to the generator carbon brushes to the servo amplifier (terminals 4+5). This voltage governed by the speed serves to control and stabilize the motor speed. Important! The new carbon brushes are 9 mm long, and must never be shorter than 3 mm. Please observe the contact pattern of the brushes also in this case. The generated d. c. voltage with max. speed is approx. 38 V and can be measured at terminals 4 + 5 of the servo amplifier. 3. Holding brake The servo control positions the backgauge precisely to the nominal position. Therefore the brake performs only a holding function and is consequently smaller than the brake on a machine of the same type, but with a normal drive system. The supply voltage is 24 V d.c., the brake air gap to be adjusted is 0.2 mm. Since April 1990 Polar uses the brake made by Mayer. This brake is identical with the previously used Lenze brake as far as the function is concerned, but the adjustment of the brake air gap is different. In the past, some motors showed broken locking pins which caused the machines to break down. This is the reason why we have been gluing the hub of the brake rotor additionally with Loctite 290 on the motor shaft since one year ago. Now, should this particular type of locking pin ( DIN 7344 - 2,5 x 16 / id. no. 203490 ) break on older motors, the damage can be eliminated on site by gluing the hub and inserting a new pin.

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Mon op GB 01 06.02.2006

List of error messages for servo amplifier BN 6454.xxxx for optimized highspeed backgauge

Error:

Motor turns in neither direction of rotation

Cause no. 1:

Soldered fuse of surge limiter BN 1778. 715 is open.

Indication:

All LED in order, bimetal clip open

Error cause:

Mains transformer badly connected on the primary side ? Excessive intermediate circuit voltage, caused by feedback of excessive braking energy, for example by constant braking action of motor. Surge limiter defective?

Elimination:

Re-establish soldered fuse connection by soldering. When doing so, make sure to retain the spring force of the bimetal.

Check:

under normal operational conditions the red LED of the surge limiter p.c. board must be OFF. It may only light up briefly when the motor is reversed.

Cause no. 2:

Short-to-ground responds

Indication:

Yellow LED (front panel) lights up; red LED on ground plate, or on older devices, red LED on additional board HL 6454.1439 on the first slot of the motherboard lights up.

Error cause:

Accidental ground of one or both motor lines to the motor housing. Caused by parting of cable in the motor line and resulting accidental ground to the cable shield. By a worn-through motor cable. By dust of the brushes which caused arcing to the motor housing.

Elimination:

In case of parting of cable install a new motor cable, check the motor, take measurement with an ohmmeter or high-voltage tester between motor housing and one motor cable. While doing so turn the motor shaft manually in order to detect a short over an entire rotation of the motor. In case of accidental ground, replace the motor. Important! For these measurements, the device must be turned off and the motor disconnected. In order to reset the stored display messages, the yellow and red LED on the device, turn the mains voltage off and re-connect it.

Check:

Under normal operational conditions the red LED on the motherboard or on supplementary board HL 6454.1439 as well as the yellow LED on the front panel must be OFF.

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Mon op GB 01 06.02.2006

Cause no. 3:

Connection error or defective supply line

Indication:

Yellow LED (ESR front side) lights up.

Error cause:

- Enable input is open (terminal 15) - Limit switch input is open (terminals 6 and 7) - Line break at these inputs - Short-to-ground, simultaneously the red LED lights up.

Elimination:

Measure the inputs (terminals 6, 7 and 15) to 0V (terminal 20) with voltmeter. The inputs must be at 0V, in case of a malfunction the inputs go up to approx. +14V. Eliminate accidental ground in motor line.

Cause no. 4:

Maladjustment or fault in motor circuit

Indication:

Red LED (ESR front side) lights up.

Error cause:

- Current limit set too low - Motor locked - Motor connection lines short-circuited one against the other

Elimination:

Check motor lines for short circuit. Switch ammeter into motor line. Current limit was too low and must be redefined. To do so, lock the motor. The pulse current will flow for some seconds. After that the devices switches back to constant current and the red LED lights up. In this condition the current is adjusted to the nominal current of the motor by means of the current limit potentiometer (front panel).

Check:

The ammeter should be monitored for some time throughout the intended operation of the machine. In any case the mean current must be sufficiently below the adjusted current limit.

Cause no. 5:

Interruption in motor circuit

Indication:

All LEDs (ESR front side) are in order

Error cause:

- Motor line interrupted - Defective motor - Defective output stage

Elimination:

- Measure nominal value input (terminals 11 and 12) - Check carbon brushes of motor, use new ones, if necessary, or replace motor. - In case of defective output stage, replace entire plug-in section.

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Mon op GB 01 06.02.2006

Cause no. 6:

Power supply error

Indication:

Green LED in ESR front panel does not light

Error cause:

- device is not switched on - no mains voltage - +/- 14V Reference voltage short-circuited

Elimination:

- Check back-up fuses of device - Verify mains voltage at transformer of device (under left-hand side cover) - Measure reference voltage + / - 14V ( terminals 13 and 14 ) to 0V ( terminal 20 )

Cause no. 7:

Activation error

Indication:

All LEDs ( ESR front side ) are in order. Motor is at a standstill at the moment or is drifting slowly into one direction

Error cause:

No nominal value available

Elimination:

Measure nominal value input (terminal 11 compared to 12)

Error:

Motor runs without any control

Error cause:

- Tachometer generator of motor badly poled - Tachometer line of motor broken - Superimposed control circuit does not coincide with the direction of rotation of the motor - Servo board jumper plugged incorrectly

Elimination:

- Check connection of motor cable - Measure tachometer voltage again (terminal 4 to 5) - Interrupt any superimposed bearing control circuit (disconnect transmitter signals) If the motor still does not run with speed control, exchange the connections of the tachometer or the motor. If the direction of rotation is correct, the bearing control circuit, if available, can be switched on again. If the motor runs without control, exchange the transmitter signals of channel 1 and 2.

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Mon op GB 01 06.02.2006

Error:

Motor is running rough and uneven

Error cause:

- Switches of reversible PI wiring are maladjusted or not closed - Potentiometer of feedback is badly adjusted (ESR front side)

Elimination:

- Verify switch position of PI wiring and set according to preset values - Adjust potentiometer of feedback. Turn counter clockwise, until the motor runs perceptibly rough, then turn slowly clockwise until the motor runs smoothly over the complete speed range. Finally check brake afterrun and drift.

Error:

Zero point cannot be set

Error cause:

- Zero loop in the wiring. - There is still one nominal value from the control system.

Elimination:

- Check wiring. - Check activation of differential amplifier in the device (white colored wire on motherboard) must be separated or removed). Verify nominal value at input (terminals 11 and 12).

Check:

Disconnect nominal value from device and bridge terminals 11 and 12. Then adjust the zero point. To do so, watch the motor shaft or measure the tachometer voltage.

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Mon op GB 01 06.02.2006

Conversion of connecting cable at servo amplifier old version

Connecting cable: 8 cores + shielding id. no. 023173 + 023174 All colored cores are twisted in pairs with a black core, each. All black cores are combined on terminal 20.

new version

The orange core which is twisted in pairs with the orange core is removed from terminal 20 and supplied to terminal 12. In order to make this quite sure, strip the insulation of the cable, if necessary. das Kabel abisolieren.

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Mon op GB 01 06.02.2006

Ramp adjustment of servo drive ( as of V 6.0 ) Type of fault:

With very smooth paper, error message „position not reached“ and brake afterrun exceeding 0,003 cm. Possible cause: Mechanical stiffness of spindle or guiding mechanism.

Adjustment:

By changing the values for starting (1) and braking stage (2) the ramp of the servo control system is modified. Home setting by factory; start and braking stage 4

Inspection:

a. Switch off display correction in the Service image. Then select the display Adjust positioning b. Enter some measurement in function 4 (positioning). c. Verify brake afterrun and drift values in the Service image. Drift value must not exceed +/• 0.060cm/sec., optimal value: 0.000 cm / sec. If the value exceeds the maximum, a new servo adjustment (see service documents) must be carried out. d. Check maximum speed in Service image. Nominal: 29.500cm/sec. - approx. 1800 r.p.m. at the spindle. e. Turn indication correction on.

Adjusting the ramp:

Test:

Select starting (1) or braking stage (2) in the „Set positioning“ image. Use the + or – key on the control unit to change the value.

a. (4) Select positioning b. Enter nominal sizes and confirm by pressing = key two times c. Backgauge goes to nominal size with re-adjusted starting and braking stages d. If there have been no errors during the inspection, you can immediately start from the data image. If there are problems, a new adjustment of the stages will be necessary. Press the C and = keys one after the other and select the new value.

Note:

Drift is the value which is set at the servo adjustment at pot P2 (on ESR unit) and designated as zero point. Drift of 0.000 cm / sec. = zero point has been perfectly set, servo motor is at a standstill after the positioning process is terminated.. However, the indicated values of drifting and maximum speed only change after a reference run has been performed!

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Mon op GB 01 06.02.2006

Parts list SERVO motor CP 1

CU

Plug-in board: Central Processor

CU

Frame

Control unit motherboard

ESR

Table

SERVO control unit

G1

SERVO

Battery for clock (2.7 V d.c.)

J1

SERVO

Bridge: Battery ( G1 ) – Voltage ON

J2

SERVO

Bridge: Nominal value zero for SERVO amplifier

K1

SERVO

relay for controller enabling

M

Table

SERVO motor

MCM

Frame

Backgauge motor control

PI

CU

Positioning Interface

S7

Table

Switches: Changeover of advance speed „fast – slow“

S 13a

Table

Switches: Changeover of return stroke „fast – slow“

T

Motor

Tachometer generator for SERVO motor

SERVO

CU

Plug-in board: SERVO control

Y17

Table

Brake lifting solenoid for backgauge brake motor

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Mon op GB 01 06.02.2006

Automatic clamping pressure regulation (PDR) The control for automatic clamping pressure regulation is divided into two blocks. A. Hydraulic control unit: Consisting of control block P1 with proportionally controlled pressure valve, one pressure sensor and two micro filters. B. Electronic control unit: Consisting of: 1 PDR plug-in board 1 CUM module 8 light sensors 8 amplifiers for the light sensors 1 stepping switch 0 – 10 for pressure presetting 1 selector switch for sensors On/Off Description of functions The hydraulic P1 control unit has been newly conceived for automated clamping pressure regulation. It is composed of: 1. proportional solenoid valve 2. pop valve 3. pressure sensor The proportional solenoid valve is controlled to open or close at a varying degree by means of the current via the PDR board. The pop valve is set at the factory to a value of 150 bars to protect the pump. The valve seat in the proportional valve can be adjusted from the rear at the P1 control unit and has also been factory set to 25 – 28 bars. This setting cannot be made when the unit is installed. ( From the front, a correction within a range of + / - 3 bars can be made). Safety clamping pressure or clamping bar speed are adjusted in the usual way. (Please, refer to the sticker on the frame pillar containing the hydraulic system). The pressure sensor is required for the data acquisition for the electronic system. Its temperature compensation allows a max. pressure deviation of 1.5 bars in the range of 10 – 100°C. For automatic clamping pressure regulation the following connections are required at the CUM module and the PDR plug-in board. Sensor amplifier 1 - 4, plug no. 825 CUM unit Sensor amplifier 5 -8, plug no. 826 CUM unit Stepping switch clamping pressure selection and sensors ON/OFF. Both units are accommodated in the control unit. Prop. valve

plug no. 701 CUM unit plug no. 702 CUM unit

Pressure sensor control block hydraulic system Diode plug 6 - pin. PDR board

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Mon op GB 01 06.02.2006

The clamping pressure selector switch is used for selecting the desired clamping pressure. If the switch for the sensors is turned off, the clamping pressure regulation works manually, i. e. the clamping pressure is adjusted according to the position of the preselection switch. Clamping pressure selector switch set to 10: on POLAR 115 / 137 = 4500 kp on POLAR 155 = 5500 kp on POLAR 176 = 6000 kp

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Mon op GB 01 06.02.2006

P1 Control unit for automatic clamping pressure regulation

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Mon op GB 01 06.02.2006

Functional principle of automatic clamping pressure regulation When the switch for the sensors is turned on, the clamping pressure regulation works automatically, i. e. the clamping pressure is regulated according to the number of sensors covered . Regardless of the material alignment on the right or left-hand side in the machine: the more sensors are covered by material to be cut, the higher will the clamping pressure be. The control unit has an internal table which differs for machine types 92 to 176. This tables includes all the pressure values (stepping switch 0 – 10) which are combined with all the sensor conditions possible and the relevant current values for the proportional solenoid valve. This special recording of all the values (teach-in program) is made at the factory for every single type of machine, and will be retained even when the control system is turned off. When the PDR board or the hydraulic block P1 is replaced, the setting must be made according to the setting instructions, items A and B. The 8 sensors integrated in the machine table supply one signal, each, to the control unit via 8 amplifiers (1- 4 on the right, 5 – 8 on the left side). At the factory the sensors are adjusted for dark paper. This can be seen from the red LEDs located at the individual amplifiers. When the sensor is covered the LED at the relevant amplifier (24 V d.c.) lights up. If no sensor is covered, all the LEDs are OFF (0V). If a readjustment is necessary, because an amplifier or fiber optic cable has been replaced or when extremely dark cutting material has been used, the sensitivity can be modified at the amplifier potentiometer (amplifiers are installed under the machine table) beneath the red LED, with the machine switched on. The sensitivity must not be increased so far that the amplifiers will be turned on by reflexions at the pressure clamp or at the lower side of the false clamp plate when the clamp is in its upper resting position. Cover the sensor with cutting material. Turn the potentiometer clockwise, until the red LED lights up. Take away the cutting material. The LED must go out. If not, repeat this procedure. When replacing a fiber optic cable, make sure that the cable will not be bent. It must be laid with a radius of at least three times the thickness of the cable. A cable is perfectly laid, when all the glass fibers on the amplifier side (unscrew cables from the amplifier) are light when the sensor is not covered. The fiber optic cable is screwed into the sensor bush with threaded sleeve ½ - ¾ turn to the cover plate. Then lock slightly. When mounting the table into the frame, please proceed with utmost care to prevent any damages to the light fiber cables under the table.

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Mon op GB 01 06.02.2006

Instructions for setting the PDR board Switch machine off . Wait, until main motor is at a standstill. Connect pressure sensor for pressure gauge to the test tap at the P1 control unit. Switch the machine on. A.

Zero calibration ( = circulation pressure ) press RESET button 1. Set mode selector (MOD) on the PDR plug-in board to „2“. 2. Use the „offset“ potentiometer to set the mode indication in such a way that the ten’s decade is „0“ and the unit decade jumps from „0“ to „1“ (see illustration, PDR board).

B.

Adjustment amplification max. pressure V = max. / P = max. 1. Leave mode selector on the PDR plug-in board at „2“. 2. Select special function „clamping without cutting“ (D). 3. Press both cut buttons and set max. pressure with potentiometer P max. POLAR 115, 137: 106 bar = 4500 daN POLAR 155: 130 bar = 5500 daN POLAR 176: 138 bar = 6000 daN 2. Press both cut buttons again, and use potentiometer V max to set the on-indicator pilot light on the ten’s decade to „ F“ and the unit decade to a value between „ E „ and „ F „ ( junction). Repeat procedures A and B. Set operating mode switch (MOD) to position „0“.

C.

Activate teach-in program 1. Set operating mode switch to position „1“. 2. Input cutting program, for example 100,000 cm + D ( Special function „clamping without cutting“ ) ET 0.50 cm + D ( Special function „clamping without cutting“ ) Adjust maximum retarding of cutting cycle with „clamping time“ rotary switch. Turn automatic knife on and trigger a cut. 3. Now all the table values (pressure values), from the minimum to the maximum pressure, stage 0 to stage 10 are now learned one by one. The displays on the PDR board show the following values: Unit decade = clamping pressure stages 0 - A ( 0 – 10 ) Ten’s decade = number of active sensors ( 0 8 )

The training process is finished when the unit decade of 0 – A and the ten’s decade of 0 – 8 have been run through. Once the teach-in program is terminated, set the operating switch to „0“ position. The operating program is activated and the display of the PDR board shows the number of activated sensors and the preselected clamping pressure stage.

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Mon op GB 01 06.02.2006

The PDR board is equipped with a battery-backed component with a 10 year life. Every time the machine is turned on, the charging condition of the battery is checked. If the battery is discharged so far that the data cannot be retained over the shut-off period of the machine, the 2-digit indicator on the PDR board will flash. The clamping pressure regulation function is maintained in this mode. But the clamping forces deviate more from the preset values. In case of an error in the internal control of the PDR board or the pressure sensor (on hydraulic control block) an emergency operation will be switched on. The clamping force will then be set to approx. 80 % of the maximum clamping force, irrespective of the position of the preselector switch. On the display of board PDR „- FF-“ is then flashing.

Program ( V 2.0 ) for automatic clamping pressure regulation Since 1988 we use a new program version (V 2.0) for the optional „clamping pressure regulation“. The PDR plug-in board, program version V 2.0 is suitable for all machines equipped with the optional automatic clamping pressure regulation. Version V 2.0 includes all the features of the preceding versions (fully-automatic) and the additional new operating mode „emergency operation“. With this operating mode, the pressure can be manually adjusted, if the sensors in the control block are defective or the input stage of board PDR has failed. Make the necessary setting for emergency operation in the following way: 1. Set the MOD switch from position „0“ to „8“ 2. Press the reset key on the PDR board 3. Turn clamping pressure stepping switch on control unit to „10“ 4. Select special function „D“ (=clamping without cutting =) and release the clamping process. Use the „P max.“ pot to set the maximum value, according to the type of machine. 115: 103 - 106 bar = approx. 4500 dN 137: 103 - 106 bar = approx. 4500 dN 155: 125 - 130 bar = approx. 5500 dN 176: 135 - 138 bar = approx. 6000 dN 5. For setting the minimum clamping pressure turn the stepping switch to „0“, then turn the Size switch to position „ 1 „ or „ F „. Trigger a clamping action by pressing the cut buttons. With position „1“ the pressure is automatically and gradually increased, with „F“ position, it is reduced. As soon as the desired value has been reached, release the cut buttons and turn the Size switch to „0“ position. The adjusted pressure values are saved and can be activated any time with the clamping pressure stepping switch (0 – 10). These values remain stored even when the machine is turned off.

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Mon op GB 01 06.02.2006

PDR board

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Mon op GB 01 06.02.2006

P 1 Oil Cycle ( 1-channel ) with proportional pressure regulating valve

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Mon op GB 01 06.02.2006

Connecting plan - automatic clamping pressure regulation

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EMC-Mon_op_GB_06.02.04

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