Computer Control Processor Control Processor

UC TV
Control
The machine is controlled by a The control processor consists The control processor consists
multiprocessor system which of: of:
consists of a control processor - a processor board, - a processor board,
and two other processors in the - a display and of - a display (remote, swing-
safety module. - a keyboard (integrated into ing display unit),
The safety module and the con- the front panel). - a keyboard (integrated into
trol processor are connected with the front panel) and of
each other via a serial data line. - a plug-on PC104 module
The control processor is powered used as a graphic proces-
by the 18 VAC supply via transfor- sor.
mer T2 (230 V/18 V, 9VA). The control processor is powered
The 5 VDC processor supply is by the 18 VAC supply via trans-
produced on the board from this former T2 (230 V/25 V, 30VA).
raw voltage. The 5 VDC processor supply is
produced on the board from this
M1265 UC Processor Board Layout raw voltage.
Optional Air Bed, Smart Clamp
S60 (K64) B27,B39
Contrast Control Display Handwheel S20 S61 S23

X801
X811 X804
X805 X806 X803 X802

Processor Mach EPROM

+ -

Power Supply Analog output unit

Backlight-Inverter
M1265 TV Processor Board Layout (without PC)
Optional Power supply for control computer
PC104 PC104 with battery Servodrive Fuse power supply
MemoryCard Service Safety module Power supply Backlight-Inverter

X811 X804 X805

X810 X808 X812 X809

X18 DPR
Processor Mach EPROM

X26 X19

X27 X21 + -

Touch Screen DIL-Switch Keyboard Serial connectar

PC104 Battery Keyboard LED's

1/01 E Service Instructions 33

Safety Module
The safety module consists of:
- a motherboard,
- 2 CPU boards,
- a comparator board.

Motherboard Layout

LH Light Guard RH Light Guard

Feedback
B61 K50,K51,K60,
K61,K86
B60
S81,S82
S51
S50
Outputs
S52,S53,S54 K52,K53,K62,
K63,K82,K83
S29

Control Processor CPU1 CPU2 Comparator

CPU Board Layout

On the CPU board, the proces-

sor is powered by the 24 VDC
supply via DC/DC converter.

Bend up PIN 31 !

1/01 E Service Instructions 34

PC Design
The PC/104 MOPSlcd4 module A dynamic RAM serves as memo- stored in a FLASH disk.
is a compact, IBM-compatible PC/ ry. The operating voltage is +5V.
AT. It accommodates the drivers The machine control program, the
for the memory card reader and language combination with the
the touch screen as well as a necessary character sets as well
VGA/LCD controller for activating as cutting programs created are
the TFT display.

Floppy upper row: Display connectar

COM2 (for PC-LINK) (for Service) lower row: Memory COM1 Control processor

X18

Chipdisk

X26

X16

Power Supply External Keyboard

(for service purposes)

Software
When changing software in the UC Software Change
PERFECTA control system, make
sure to use compatible versions For the UC, only one programmed Change the EPROM on the con-
for the control processor and the 27C2001 or 27C020 EPROM is trol processor board whith the
safety module. required for saving the machine machine turned off. Important:
All U/V 05... control processor control program and the language Ensure proper pin positions. The
software versions require at least combination. notch in the EPROM must face
a TD 03m (or later) software ver- Its identification label contains the mark in the base (i. e. towards
sion on both processor boards of the version number of the control the main switch).
the safety module. program and of the language com- Caution: EPROMS are sensitive
bination, e. g. U05F_10. to electrostatic charging. There-
fore, properly connect yourself to
earth before handling an EPROM.

1/01 E Service Instructions 35

TV Software Change

For this software change, always

use MCs having ident number 6
(from software version V4_06 on).
Do not use MCs with software
versions from V4... on for soft-
ware changes on older control
systems, for they would become F1 reset Sys Dat
useless because of the modified F2 delete Prog Dat
touch screen.
F3 language
For the same reasons, the use of
MCs with software versions befo- F4 load from MC
re V4... is not admissible either F5 start
for control systems which this
Service Manual applies to.

When changing the software on

the PERFECTA-TV, keep the fol-
lowing sequence under any cir-
cumstances:

1. Turn off the machine and chan-

ge the EPROM on the control 5. Press the F4 key, „LOAD“; you Depending upon the individual
processor board (refer to UC). will be prompted: „PLEASE IN- cases, you can use the F1 key to
SERT MEMORY CARD“. call the menu mentioned under 2.
2. Start the machine. and delete the system data (the
6. After the reading and the trans- measuring system of the machine
3. When the start routine runs, the fer of the memory card contents will get lost, restoring factory ca-
display shows a key in the upper (control and language data) into libration from the service menu
middle. Press this key! the machine memory, the com- will be required) and/or use the F2
pressed files are automatically key to delete the stored cutting
4. A menu with function keys tested and unpacked. Then the programs, thus to re-initialise the
appears: machine will restart. If any error is program memory. The F3 key
found during the testing of the enables you to select one of the
transferred data, the machine will available languages the machine
restart using the old software. will start in. Your language choice
will be displayed in the upper right
corner of the screen.

Replacing the two processor

packages on both safety module
CPU boards
The program version number of
the safety processor is shown on
the label on the processor pack-
age.
Both processor packages must
have the same version number.
The program version number need
not coincide with the number on
the control processor.

1/01 E Service Instructions 36

Settings/
Operating Data
Act. : 0200 00 mm 5x
Des. : 0000 00 mm Servicemenu
SF
From the settings menu, you can
change the stroke limit, the knife
thickness, the clamping time ex-
tension, the "clamping only" time, 1x
the air handling when programming PERFECTA UC
backgauge destinations as well
as the active language.
In addition and for the UC control
system, this menu includes the
speed settings (vmax, start und
stop) for approaching destinations Operating date
through the keyboard or by pro-
Hours : 000050h
grams. The speed settings for the
Cuts :
TV are contained in a specific
speed menu which can be called 00000588
from the settings and the service Daycount : 00285
menus. Lubric. : 8600
The operating counter shows the
Knifechan : 80000
total hours and the total number of
cuts of the machine. These valu-
es cannot be reset.
The daily counter, lubrication cy-
cle counter, and the knife change
counter values can be changed
with the plus/minus keys. All va- Settings
Stroke : 0
lues are referred to the number of +,00 mm
Knifed. :
cuts made. Refer to handling in- 0,0 s
Clamptime :
struction in chapter "Operating
Vmax : 210
data".
Start : 0
Stop : 1
at : 0
Clmp only : 0,0 s
Measurem.: mm
UC : Language : 0

Exit the menu with the "C“ key.

All changes made will be ac-
cepted.

1/01 E Service Instructions 37

TV:

M
ACT :
0945 55 mm

DES :

0000 00 mm

? 1x

Settings
Smart clamp:
Masurement:
-
mm
?
Knife thick: +0.00 mm
Clamptime: 0.0 s
Air: -
Clamping only: 0.0 s
Knock-up: 0300 mm
Push-out: 0300 mm
Language: ENGLISH
Dir. of rot.:
Lay side:
Grafic delay: -

General Counter SF
Hours: 000050
Cuts: 00000588
Day counter: 000285
Lubric. count.: 8600
Knifechange: 800000

Save the settings with the enter

key. Without saving the old valu-
es are kept.

1/01 E Service Instructions 38

Service Menü
(UC)
Act. : 0200 00 mm 5x
Press the upper function key 5
times to call the service menu.
Des. : 0000 00 mm

PERFECTA UC

The following image appears Software version no. Language combination number

With the aid of the "+“ and "-“

Servicemenu
function keys, selection can be 05F/10 Scroll up
made among the following me-
nus: Calibration Scroll down

- Calibration Call menu

- I/O Test =
- Sensor-Test
- Operating Data
- Character Set 1
- Character Set 2
- Texts

Call the menu with the "=“ function

key.

Exit the menu with the "C“ key. C

M
ACT :
Service Menu
(TV) 0945 55 mm

DES :
Touch the PERFECTA logo key.
The setup menu appears.
0000 00 mm

?
1/01 E Service Instructions 39
To call the service menu, press 5
times the place on the screen Settings
where the PERFECTA had ap-
peared.
Smart clamp:
Masurement:
-
mm
?
Knife thick: +0.00 mm
The service menu appears. Clamptime: 0.0 s
Selection can be made among Air: -
the following menus: Clamping only: 0.0 s
Knock-up: 0300 mm
- Speed Push-out: 0300 mm
Language: ENGLISH
- Sensor Test
- I/O Test Dir. of rot.:
Lay side:
- System-Parameters Grafic delay: -
- Calibration 5x
General Counter SF
Call the menu by touching the Hours: 000050
corresponding key. Cuts: 00000588
Day counter: 000285
Lubric. count.: 8600
Knifechange: 800000

Software Version Software Version in

in Flash (PC) EPROM (Control Processor)
Any changes in the menus must
be confirmed with the enter key
as, otherwise, the previous set-
tings are kept.
Service Speed
Version:
V4.07 Sensor - Test
EPROM
Exit the menu with the "C“ key. V05F IO - Test
ENGLISH.TXT
C
V4.6 System-Parameter
EN: STANDARD
Calibration

Current Language
and Version No.
Language Abbreviation
and Chraracter Set
Language Abbreviations:

DE German IT Italian SL Slovenian

EN English NL Dutch KR Croatian
FR French PL Polish FI Finnish
SP Spanish PR Portuguese
CH Chinese RO Rumanian
CZ Czech RU Russian
DK Danish SK Slowakian
GR Greek SW Schwedish
HU Hungarian TK Turkish

1/01 E Service Instructions 40

I/O - Test Menu
The I/O test can be called I/O- Test
- via the service menu, or 7810 -18 -20 P3
- after any error message
(error remains stored) FF FC FF 30
by pressing the top function key P5 P4 P1 P0
(UC), or by touching the screen
(TV), respectively. 81 32 7C 00
Diffanz. Off
If the service menu is called up,
the current machine signals are
displayed. In case of any errors
the machine signals are stored
and can be displayed.

The following image appears:

I / O - Test
This menu shows the machine
signals to the control and safety 7810 7818 7820 P3
processors as hexadecimal num- FF FE FF 70
bers (0...9, A,B,C,D,E,F).
P5 P4 P1 P0
Eight signals, in each case, are 81 32 7C 00
one port, and are represented as
two HEX numbers (2 x 4 signals).

Ports 7810, 7818, 7820 and P3

represented in the top line are in
the control processor.
Ports P0, P1, P4 and P5 shown in
the bottom line are in the safety
module.

Valence HEX
When a signal is active (=1), it
becomes a hex number of corre- 8 4 2 1 no.
sponding valence. 0

X 1

X 2
On the UC, the difference display
X X 3
can also be activated/deactiva-
ted. X 4

X X 5

X X 6

X X X 7

X 8

X X 9

X X A

X X X B

X X C

X X X D

X X X E

X X X X F

1/01 E Service Instructions 41

 Port x
Bit 7 6 5 4 3 2 1 0
Valence 8 4 2 1 8 4 2 1
Example: Signals 2, 3, 6 and 8 Signal
are active: 8 7 6 5 4 3 2 1
No.

The display reads HEX number

A6.
Port x
Bit 7 6 5 4 3 2 1 0
Valence 8 4 2 1 8 4 2 1
Signal
8 7 6 5 4 3 2 1
No.

8+2 4+2
The following table shows the
signal line assignments: A 6
(I) = input (O) = output

Safety processor
Port 0:

Bit: 7 6 5 4 3 2 1 0 Signal Remark

Valence 8 4 2 1 8 4 2 1

X (I) Light guard channel 1 0 = beam free

X (I) Light guard channel 2 0 = beam free

X (I) Light guard channel 3 0 = beam free

X (I) Light guard channel 4 0 = beam free

X (I) Light guard channel 5 0 = beam free

X (I) Light guard channel 6 0 = beam free

X (I) Light guard channel 7 0 = beam free

X (I) Light guard channel 8 0 = beam free

Safety processor
Port 1:
Bit: 7 6 5 4 3 2 1 0 Signal Remark

Valence 8 4 2 1 8 4 2 1

X (I) Light guard channel 9 0 = beam free

X (I) Light guard channel 10 0 = beam free

X (I)"Clp+cut enable" from control processor 0 = C+c enable

X (I) "Auto" from control processor 0 = Auto on

X (I) "Cut" from control processor 0 = Cut on

X (I) "Clamp" from control processor 0 = Clamp on

(I) "Pressure reached" from control

X 0 = Pressure reached
processor

X (I) "Stock free" from S29 0 = Stock free

1/01 E Service Instructions 42

Safety processor
Port 4:

Bit: 7 6 5 4 3 2 1 0 Signal Remark

Valence 8 4 2 1 8 4 2 1

X (I) Catch down 0 = operated

X (I) Catch up 0 = operated

X (I) B60 valve monitoring 0 = closed

X (I) B61 valve monitoring 0 = closed

X (I) S50 LH knife pushbutt. 0 = operated

X (I) S51 RH knife pushbutt. 0 = operated

X (I) "Clamping only" from control processor

X (I) "Extendet clamping" from control proc.

Safety processor
Port 5:

Bit: 7 6 5 4 3 2 1 0 Signal Remark

Valence 8 4 2 1 8 4 2 1

X (I) Cross coupling

X (I) K50 cut contactor 1 = operated

X (I) K51 cut contactor 1 = operated

X (I) K60 clamp contactor 1 = operated (x

X (I) K61 clamp contactor 1 = operated (x
X (I) S52 knife upward 1 = operated

X (I) S53 knife downward 1 = operated

X (I) S54 knife up 1 = operated

x) is not displayed from software

vision TD03k and up.

Control processor
7810:

Bit: 7 6 5 4 3 2 1 0 Signal Remark

Valence 8 4 2 1 8 4 2 1

X stock width Bit 0 presently not used

X stock width Bit 1 presently not used

X stock width Bit 2 presently not used

X stock width Bit 3 presently not used

X options Bit 0

X options Bit 1

X options Bit 2

X options Bit 3

1/01 E Service Instructions 43

Control processor
7818:

Bit: 7 6 5 4 3 2 1 0 Signal Remark

Valence 8 4 2 1 8 4 2 1

X S23 false clamp switch 0 = false clamp removed

X B27 backgauge rear limit switch 0 = operated

X B39 "calibrate" proximity switch 0 = operated

X K64 pressure switch 0 = pressure reached

X Main motor ON/OFF

X S61 clamp up switch Normally not used

X S68 "clamping only" switch 0 = operated

X S68 "clamp lock" switch 0 = operated

Control processor
7820:

Bit: 7 6 5 4 3 2 1 0 Signal Remark

Valence 8 4 2 1 8 4 2 1

X S20 backgauge forward switch 0 = operated

X S20 backgauge reserve switch 0 = operated

X S20 backgauge fast switch/Andruck 0 = operated

X S20 backgauge slow switch 0 = operated

X Alarm from servo 0 = operated

X In position from servo 0 = operated

X Reserve signal from safety processor 0 = operated

X Only for analogue inverter option 0 = RUN

Control processor
Port 3:
Display currently unimportant.

1/01 E Service Instructions 44

Keyboard Code
(UC)

In the I/O test, the function of the I/O- Test

keyboard and the transmission of 7810 -18 -20 P3
the key codes to the control pro-
cessor can be checked. FF FC FF 30
P5 P4 P1 P0
Pressing any key will make its
associated code appear in the 81 32 7C 00
display lower left-hand corner: 26
Diffanz. Off

Keyboard code

UC key codes:

Diffdisp Off/ON

Exit this menu by pressing the "C“

key. C

1/01 E Service Instructions 45

Sensor Test Menu Hexadecimal Decimal

This menu is required for adju-

sting and checking the measu-
ring system.
Calling the "Sensor test“ menu Sensor-test
will make the following image Counter :
appear: 004D4E 019790
The top line (Counter) reads the Sensor : 0 019826
current count as a hex number
followed by a decimal number.
One pulse each corresponds to a Switch : 0 020006
hundredth of a millimeter, i. e. a
count of 20000 is 200.00 mm.

Behind Sensor, the state of the

"zero pulse“ signal line from the
Servo is displayed. Sensor - Test
"0“ = zero pulse not active, "1“ = Counter: 004D4E 019790
zero pulse active. Zero sensor: 0
In addition, an acoustic signal is Count: 004D72 019826
caused when the zero pulse is 0
Switch (B39):
active.
The zero pulse is active every Count: 004E26 020006
4 mm.

In the second line behind Sensor,

the count when the zero pulse is
being passed is saved.

In the last line behind Range, the

status of proximity switch B39
responsible for the calibration ran-
ge is indicated:
"0“ = operated, "1“ = not operated.

Behind, the count when the proxi-

mity switch is reached (pulse
edge) is saved.
Set proximity switch B39 so that
it becomes active approx. 2 mm
before the first zero pulse ap- 2. Zero puls
pears in front of the measurement
1. Zero puls
of 200.00 mm when being approa-
ched from behind, i. e. when a
zero pulse appears at 19974, the
proximity switch must become
active at a count of 20174 ± 50.
B39 B27

200 ± 50 Impulse

1/01 E Service Instructions 46

Activating the Differential Dis-
play
UC: I/O- Test
7810 -18 -20 P3 Plus key
Call the "I/O-Test" item in the
service menu. FF FC FF 30 Minus key
Move to the "DIFFDISP" menu P0
P5 P4 P1
item with the cursor keys and Cursor key
select with the "+" or "-" key, 81 32 7C 00
respectively.
Diffanz. Off
Select "ON" for differential dis-
play and exit the menu with the
"C" key.

Act. : 0200 00 mm
Des. : 0000 00 mm

PERFECTA UC
18 17 234 20

The individually displayed

numbers (from left to right)
stand for the following:

UC:

18 Actual (input distance between reading xxxx.00 and

actual zero pulse position in the servo motor encoder)

17 Desired (expected distance between reading xxxx.00 and

actual zero pulse position in the servo motor encoder)

234 Counter (number of travel events since the last zero pulse check)

20 Safety module status display

1/01 E Service Instructions 47

TV:
Call the "System Parameters" item
from the service menu. System - Parameter ?
Use the cursor keys to select Monitor: Color (sw)
"Diff. Display", activate it with "+"
and press the enter key to con- Diff. Display: - (+)
firm. Program loading: - (+)

The basic screen form of the

machine will now show the follow-
ing information (from left to right):

The first four numbers are analo-

gous to the UC. An additional digit
on the right shows the battery
status of the MemoryCard just
inserted:
-3 = No MemoryCard inserted.

-2 = PC Link, external programming via cable active.

-1 = Battery test not supported (34-pole Panasonic MC).

0 = Discharged.

1 = Nearly discharged.

2 = Fully charged.
Act: 18 Des: 17 C: 234 Status: 20 Batt: -3
TV and UC: ACT :
Always set the handwheel to the
slowest forward travel stage to
0945 55 mm

check the zero pulse position.

DES :
One zero pulse appears every
4 mm (once per motor turn).
The tolerance covers ± 3 pulses.
0000 00 mm

If this tolerance range is ex-

ceeded, any further backgauge
movement will be disabled and
you will be prompted "Calibrate
machine first!". ?
Once a machine has already been
set, calibrating from the settings
menu (without entering any meas-
urement, without length measur-
ing) will be sufficient.

1/01 E Service Instructions 48

The same as for the I/O test, the
safety processor status is display-
ed as a hexadecimal number.

Bit: 7 6 5 4 3 2 1 0 Signal Remark

Valence 8 4 2 1 8 4 2 1

X Error when power ON 1 = error

X Knife overrun 1 = error

X Error at knife resting position 1 = error

X Knife up 1 = S52 operated

X Backgauge 1 = no backgauge travel

X Light guard 1 = beams free

1 = manual pushbuttons
X Two- hand control
pressed

X Full auto 1 = full auto ON

Settings
Speed Menu Stroke : 0
Knifed. : +,00 mm
Clamptime : 0,0 s
Vmax : 210
After you have called the "Speed"
Start : 0
menu on the TV or the settings
Stop : 1
menu on the UC, the following
screen will appear: at : 0
Clmp only : 0,0 s
The speed settings can be altered Measurem.: mm
with cursor key ">“, and with the Language : 0
plus "+“ or minus "-“ key, respec-
tively.

The Vmax speed used for posi-

tioning the backgauge through the
numerical keyboard or by the pro- Speed ?
gram can, if required, be increased
v - max: 210
up to "300" or decreased down to
"001" (adaptation to the stock). Damping
This setting is independent of the
Start ramp: 0
handwheel speed.
The ramps for the backgauge tra- Stop ramp: 1
vel are freely selectable indepen-
dently of one another in seven
steps (0...6), with Start correspon-
ding to the (acceleration) ramp at
the beginning of the movement
process and Stop to the (braking)
ramp at its end.
The higher the number set is, the
more time will be used for the
execution of the respective ramp, i.
e. the ramps will become more The factory-set default values of
gentle as their numbers grow. the speed parameters are:

Vmax = 210
Start = 0
Stop = 1

1/01 E Service Instructions 49

Character Set Menu
UC only:

The two character sets contai- !"#0%'()*+,-./~°

ned in the respective EPROM
can be displayed in the two CHA- 0123456789 <=>
RACTER SET 1 and CHARAC- abcdefghijklmno
TER SET 2 menus.
pqrstuvwxyz:;?ß
Character set 1 display: äöü
(example)

Character set 2 display:

ÆÞÛµØýÒÚõÙ
(example)

Texts Menu
UC only:

After calling this menu, you can

view the text lines of all languages Servicemenü
available by using the upper and Servicemenu
lower softkeys. Menu service

Text lines display:

(example)

0005

1/01 E Service Instructions 50

Knife Control
(Control Switches)
The switches are represented as
- The functions of the control swit- hex numbers:
ches are displayed in the service
menu (I/O= test):
Port 5
I/O- Test Bit 7 6 5 4 3 2 1 0
7810 -18 -20 P3 Val. 8 4 2 1 8 4 2 1
FF FC FF 30 S54 S53 S52

P5 P4 P1 P0
00 "0" = switch not operated.
81 32 7C
"1" = switch operated.

Control switches
I / O - Test
S52, S53, S54
7810 7818 7820 P3
FF FE FF 70
P5 P4 P1 P0
81 32 7C 00

- When the knife is cranked by

hand, the following values must
appear in the display:

1/01 E Service Instructions 51

PSG16 Light
Guard
Light guard channel numbers:

LH side Transmitter RH side

Receiver

The channels are represented as

HEX numbers:

Port 1 0
I/O- Test Bit 1 0 7 6 5 4 3 2 1 0
7810 -18 -20 P3 6A 7A 8A 9A -- 1A 2A 3A 4A --
Channel
FF FC FF 30 no. 6B 7B 8B 9B -- 1B 2B 3B 4B --

P5 P4 P1 P0
"0" = beam path free
81 32 7C 00 "1" = beam path interrupted

Light guard signals

Hex- number at covered beam

Two beams, in each case, form
one channel in the display (e. g.
6A and 6B,...). Hex-
Covered beam
number
Depending on the cutting width,
only one beam, in each case, of 1A or 1B C 10
the three 9B’, 9B’’ and 9B’’’ is
active at a time. 2A or 2B C 08
Coding is effected in the connec- 3A or 3B C 04
tion cable between the safety pro-
cessor and the light guard. 4A or 4B C 02
6A or 6B E 00

Channel 9B' = P76 7A or 7B D 00

8A or 8B C 80
Channel 9B'' = P115/132/168
9A or 9B C 40
Channel 9B''' = P92

1/01 E Service Instructions 52

Error Messages

Error Message Possible Causes

N0
1 CALIBRATE MACHINE FIRST -Control processor first-time start up
-RAM battery discharged
-Measuring system error (zero pulse offset).
-Voltage failure wihle backgauge is moving.
2 DESIRED MEASUREMENT TOO BIG -Absolute measurement input bigger than cutting table length.
-Relative measurement input bigger than possible travel from
current backgauge position to front.

3 DESIRED MEASUREMENT TOO -Absolute measurement input smaller than minimum scrap width
SMALL (remove false clamp, if possible).
4 DESIRED MEASUREMENT OUT OF Currently not used
TOLERANCE

5 LIMIT SWITCH REACHED Currently not used

6 PLEASE CALIBRATE MEASURING Currently not used

SYSTEM

7 KNIFE OVERRUN S52 de-energizing main clutch too late (referto page 52).

8 START TEST DETECTING ERROR -PRESS "C" key to display error message.
-Call I/O test and check stored machine signals.

9 CATCH NOT LOCKING IN -Check S81 and S82 functioning.

-Check S52/S53/S54 sequence.
-Check S29 functioning.
-Check S60.
10 CORRECTION ERROR

11 RAM SET TO DEFAULT VALUES -Control processor first start-up

-RAM back-up battery discharged
-Back-up battery removed
12 UNLOCK HANDWHEEL -S20 backgauge switch being opereted when machine was
powered.
13 ZERO DIVISION

14 NUMERATOR > DENOMINATOR -For inch measurement entries, e.g. "10...5/4" instead of "11...1/4".

15 LIGHT GUARD SIGNAL

16 STOCK FREE SIGNAL -Check S29 for proper functioning.

17 PRESSURE REACHED SIGNAL -Check S60 and K64.

18 CONTROL PROCESSOR CLAMP Check data cable between control processor and safety module for
SIGNAL firm seating
19 CONTROL PROCESSOR CUT Refer to 18
SIGNAL
20 CONTROL PROCESSOR AUTO Refer to 18
SIGNAL

1/01 E Service Instructions 53

 Error Message Possible Causes
No
21 CONTROL PROCESSOR CLAMP + CUT Refer to 18
ENABLE SIGNAL
22 TWO-HAND PUSHBUTTON -S50 or S51 was operated when machine was powered.

23 VALVE MONITORING -For machines with valve monitoring, check valves.

-For machines without valve monitoring, check contacts of
K60 and K61.
24 CLAMP CONTACTOR CONTACTS -Check contactors K60 and K61.

25 CUT CONTACTOR CONTACTS -Check contactors K50 and K51.

26 KNIFE DOWN SWITCH -Check S53 function

27 KNIFE UP SWITCH -Check S52 function

28 SAFETY MODULE DETECTING ERROR -Press "C" key to display error message.
-Call I/O test and check stored machine signals.

29 KNIFE SWITCH UPPER DEAD CENTRE -S54 and S53 operated at the same time.
AND DOWN SIGNAL -Swith S54 sticks (remains operated).
-Time gap between S54 and S53 actuation too short (refer to
page 52).
30 KNIFE SWITCH UPPER DEAD CENTRE -S52 and S54 operated at the same time.
AND UP SIGNAL -Switch S54 sticks (remains operated) (refer to page 52).
31 NO UPPER DEAD CENTRE KNIFE -Switch S54 not operated.
SWITCH SIGNAL -Main clutch switched off by S52 too early (refer to page 52).

32 SAFETY SYSTEM DEFECTIVE -Replace safety module!!!

(comparator defective) Checking is done during the start test.
-Check cards in safety module for proper seating.

33 SAFETY SYSTEM DEFECTIVE -Replace safety module!!!

Checking is done during the cutting cycle.
-Check cards in safety module for proper seating.

34 CALCULATION OVERFLOW

35 STEP 1 ABSOLUTE MEASUREMENT

ONLY (UC and TV only)
36 PROGRAM TOO DEEPLY NESTED -Too many loops opened in programming.
(UC and TV only)
37 ENCODER FAILURE Currebtly not used.

38 PILE DOES NOT EXIST -A pile memory not agreed upon or deleted has been called for
(TV only) processing.
39 NO MORE PILE -A maximum of 8 pile memories can be used only (refer to
(TV only) Operating Instructions).
40 DATA TRANSFER (L. O. S.) -Defective or no communication with suprior computer
(serial data transfer only) network.
41 SWITCH S61 NOT CLOSED -For guillotines with linked peripherals:
Backgauge locked by peripherals.

1/01 E Service Instructions 54

 Error Message Possible Causes
No
42 SAFETY PROCESSOR DISABLING -Knife not in home position at upper dead centre.
BACKGAUGE Use knife pushbuttons to execute a complete cut.
43 MOTOR OUTPUT STAGE ALARM -Alarm can be cancelled with C key.
-Check backgauge for mechanically free run.
-Check proximity switch B29 (rear end position) for correct
setting.
-Check cable connections (on servo motor, on servo drive, on
control processor).
44 MOTOR OUTPUT STAGE NO ZERO -Control processor does not detect zero pulse from servo
PULSE drive.
-Check servo drive power supply (green LED lit?, fuse F1 O.
K.?)
-Check cable connection between servo drive and control
processor.
45 CHECK SUM ERROR IN PROGRAM -Program memory re-initialisation required.
MEMORY Fot this purpose, turn off machine and re-power with program
key held pressed until full readiness for operation is restored. If
this function is not yet supported by the software used, pull
battery for at least 60 s.
Important: In such case, calibrate machine from service menu
(with length measuring) to restore measuring system under
any circumstances.

46 CHANGE BATTERY -Change RAM back-up battery on control processor card.

99 WRONG ERROR MESSAGE -Commmunication error between front processor and PC unit.
(TV only)

1/01 E Service Instructions 55