Operating Instructions

(Translation of "Originalbetriebsanleitung")

High-Speed Cutter POLAR

78 X / 78 XT
92 X / 92 XT
115 X / 115 XT / 115 XT Autotrim
137 X / 137 XT / 137 XT Autotrim
155 X / 155 XT / 155 XT Autotrim
176 X / 176 XT / 176 XT Autotrim
 Table of contents Page
Control Panel 78 XT - 176 XT ........................................................................................................ E - 4 Automatic Operation ................................................................................................................. K5A - 1
Control Panel 78 X - 176 X ............................................................................................................. E - 5 Introduction .................................................................................................................................. K5A - 2
Operating Elements (X Models) ..................................................................................................... E - 6 Functions of the menu keys ........................................................................................................ K5A - 3
Special Function Moduls on Operating Panel (XT Models) ........................................................... E - 7 Basic Menu: Program-Data ......................................................................................................... K5A - 4
Operating Elements (XT Models) ................................................................................................... E - 8 Basic Menu: Program Information .............................................................................................. K5A - 6
Touch-Screen Calibration (XT Models) .......................................................................................... E - 9 Basic Menu: Program Directory .................................................................................................. K5A - 7
Operation / Functionality of the Display ...................................................................................... E - 10 Basic Display: Main Menu (Function Survey) ............................................................................. K5A - 8
EasyMode (XT) ............................................................................................................................. E - 13 Cursor Movement in Basic Menu (types 78 X - 176 X) ............................................................... K5A - 9
PowerMonitor (Optional on XT Models with OptiKnife feature) ................................................... E - 13 Automatic Backgauge Adjustment through Numerical Keypad ................................................ K5A - 10
CountMonitor (Optional on X and XT Models) ............................................................................. E - 14 Moving Backgauge to a Nominal Position (Positioning) ........................................................... K5A - 11
Explanation of Pictographs on the Display .................................................................................. E - 15 Deletion of a Wrong Input in Input Section ............................................................................... K5A - 11
Chapter survey ............................................................................................................................. E - 18 Input Error: Value of Nom. Backgauge Position too Low/High ................................................. K5A - 11
Introduction ................................................................................................................................... E - 19 Selection of a Free Program ..................................................................................................... K5A - 12
Selecting a Program .................................................................................................................. K5A - 13
Technical Data / Machine Layout / Transport and Installation of the Machine /Safety Storage of Measurements ......................................................................................................... K5A - 15
Relevant Machine Elements / Description of the Machine ..................................................... K1 - 1 Setting Up a Cutting Program, Example 1 ................................................................................ K5A - 16
Transport and Installation of the Machine ..................................................................................... K1 - 4 Setting Up a Cutting Program, Example 2 ................................................................................ K5A - 17
Place of Installation ....................................................................................................................... K1 - 4 Step Selection ............................................................................................................................ K5A - 18
After the Installation of the Machine .............................................................................................. K1 - 4 Select Step Number .................................................................................................................. K5A - 18
Power Supply ................................................................................................................................. K1 - 5 Erase Step(s) With Number(s) .................................................................................................. K5A - 18
Type Plates .................................................................................................................................... K1 - 5 Transform ET-Block Using Absolute Positions ......................................................................... K5A - 20
Safety Relevant Machine Elements .............................................................................................. K1 - 6 Copy Program Steps into Clipboard (Program Section) ........................................................... K5A - 20
Safety Signs (for U.S. and CAN. specifications only) ................................................................... K1 - 8 Insert/Append from Clipboard ................................................................................................... K5A - 21
Safety Signs .................................................................................................................................. K1 - 9 Correction of an Input ................................................................................................................ K5A - 22
Technical Data ............................................................................................................................. K1 - 10 Automatic ON/OFF (Automatic Forward) .................................................................................. K5A - 23
Permissible Environmental and Operating Conditions ............................................................... K1 - 10 Automatic Knife OFF ................................................................................................................. K5A - 24
Hydraulic Data ............................................................................................................................. K1 - 10 Running a Cutting Program ....................................................................................................... K5A - 25
Safety Precautions ...................................................................................................................... K1 - 10 Storage of Program Informations .............................................................................................. K5A - 26
Residual Risk ............................................................................................................................... K1 - 10 Deletion of a Step Number (Measurement / Comment) ........................................................... K5A - 28
Safety Inspection ......................................................................................................................... K1 - 10 Deletion of Several Step Numbers (Program Section) ............................................................. K5A - 28
EC-Conformity Declaration .......................................................................................................... K1 - 12 Deleting a Program / Several Programs ................................................................................... K5A - 29
Program Directory: Copy Programs .......................................................................................... K5A - 32
Safety ............................................................................................................................................ K2 - 1 Program Directory: Set / Reset Program Protection ................................................................ K5A - 34
Inserting of Measurements into a Program ............................................................................... K5A - 36
Start - Up ....................................................................................................................................... K3 - 1 Storing of Measurements According to Printed Image ............................................................. K5A - 37
Switching Machine ON .................................................................................................................. K3 - 2 Compensation of Variations in Print (78 XT - 176 XT) .............................................................. K5A - 38
Turning Machine OFF .................................................................................................................... K3 - 2 Calculator Functions .................................................................................................................. K5A - 39
Machine Identification .................................................................................................................... K3 - 3 Negative Sign ............................................................................................................................ K5A - 40
Measurement Display and Measurement System ........................................................................ K3 - 4 Using Backgauge Position of Calculations ............................................................................... K5A - 40
Cut Correction ........................................................................................................................... K5A - 41
Manual Operation ........................................................................................................................ K4 - 1
Fine Adjustment by Hand .............................................................................................................. K4 - 2 Machine Functions and Additional Functions (Menu Keys) ................................................ K5B - 1
Setting of Measurements (Backgauge Movement) by Hand ........................................................ K4 - 2 Main Menu (Function Survey) ..................................................................................................... K5B - 2
Cutting Line Indicator, Mechanical with Clamp ............................................................................. K4 - 3 Main Menu: Language ................................................................................................................. K5B - 3
Cutting Line Indicator, Optical ....................................................................................................... K4 - 3 Main Menu: Measuring Unit ........................................................................................................ K5B - 3
Clamping and Cutting .................................................................................................................... K4 - 3 Main Menu: Copy Program ......................................................................................................... K5B - 4
Clamp Pressure Adjustment ......................................................................................................... K4 - 4 Copy a Program Within Memory Segment A or B, Resp. ........................................................... K5B - 5
Setting the Clamping Time Prior to Cutting .................................................................................. K4 - 4 Copy Several Programs Within Memory Segments A or B, Resp. ............................................. K5B - 6
Light Barrier ................................................................................................................................... K4 - 4 Copy a Program/Several Programs From Memory Segment A or B, Resp., to Memory
Clamping with False Clamp Plate ................................................................................................. K4 - 6 Segment B or A, Resp. ................................................................................................................ K5B - 6
Flexible False Clamp Plate (Optional Equipment) ........................................................................ K4 - 6 Copy the Complete Contents of Memory Segment A or B, Resp., to Memory Segment B
Air Table ......................................................................................................................................... K4 - 7 or A, Resp. ................................................................................................................................... K5B - 7

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Table of contents Page
Main Menu: Block Programming ................................................................................................. K5B - 8 Auxiliary Functions: Difference of Positions (XT) ........................................................................ K5F - 3
Selection of an Input Parameter with Block Programming ....................................................... K5B - 18 Auxiliary Functions: Correction of Cut Position .......................................................................... K5F - 4
Correction of an Input Parameter with Block Programming ..................................................... K5B - 18 Auxiliary Functions: Skip Cutting Warning On ............................................................................ K5F - 4
Main Menu: Production Report ................................................................................................. K5B - 21 Auxiliary Functions: CountMonitor (Progress Control) ................................................................ K5F - 5
Main Menu: Sheet Size Tables .................................................................................................. K5B - 23 Auxiliary Functions: PL-Block Branch Table (XT) ....................................................................... K5F - 5
Main Menu: Service ................................................................................................................... K5B - 23 Auxiliary Functions: Correction of Position (XT) ......................................................................... K5F - 7
Main Menu: Knife Thickness Compensation ............................................................................ K5B - 24 CountMonitor (Optional on X and XT) ......................................................................................... K5F - 8
Main Menu: Maintenance Cut Counter ..................................................................................... K5B - 25
Main Menu: Preset Cut Counter (XT) ........................................................................................ K5B - 26 Menu Key: Machine Parameters (Program-/Step Parameter) .............................................. K5G - 1
Main Menu: Preset Functions ................................................................................................... K5B - 27 Functions of the "Machine Parameters" (Program -/Step Parameter) menu ............................ K5G - 2
Main Menu: Press Material (Fix Clamp) .................................................................................... K5B - 39
Main Menu: Correction for Material (XT) ................................................................................... K5B - 40 Menu Key: User Defined Additional Functions (XT) ............................................................. K5H - 1
User Defined Additional Functions .............................................................................................. K5H - 2
Menu Key: Additional Functions ............................................................................................. K5C - 1
Storage of Additional Functions with Cut Size ............................................................................ K5C - 2 Autotrim 80 (option) ................................................................................................................. K5K - 1
Subsequent Storing of Additional Functions ............................................................................... K5C - 2 Autotrim 80 (option) ..................................................................................................................... K5K - 2
List of Additional Functions ......................................................................................................... K5C - 3
EasyMode (XT) .......................................................................................................................... K5C - 10 Knife Change ................................................................................................................................ K6 - 1
Swivel Backgauge (optional equipment) ................................................................................... K5C - 15 Knife Change "OptiKnife" on Types 115, 137, 155, 176 ............................................................... K6 - 2
Tilting Backgauge (optional equipment) .................................................................................... K5C - 17 Knife Change with Con-Rod Adjustment (Option, on Types 115, 137, 155 only) ......................... K6 - 8
Fixomat (optional equipment) .................................................................................................... K5C - 19 Adjustment of knife bar on types fitted with con-rod adjustment ............................................... K6 - 14
TwinClamp (optional equipment) ............................................................................................... K5C - 23 Knife Change "OptiKnife" on Types 78 and 92 ........................................................................... K6 - 15
Clamp Unit at Knife (optional equipment) ................................................................................. K5C - 26 Changing of Cutting Stick ............................................................................................................ K6 - 21
Retractable Side Gauge (optional equipment) .......................................................................... K5C - 27
Stack Lifts, fixed with Semi-Automatic Height Control (optional equipment) ........................... K5C - 28 Malfunctions / Breakdowns ........................................................................................................ K7 - 1
Mechanical Breakdowns ............................................................................................................... K7 - 2
Menu Key: Program Functions ............................................................................................... K5D - 1 Electrical Malfunctions / Breakdowns ........................................................................................... K7 - 4
Program Functions: Nominal Position ........................................................................................ K5D - 2 Start - Up Breakdown: Scan Reference Point / Auxiliay Mode ..................................................... K7 - 5
Subsequent Storing of a Comment into an Existing Program .................................................... K5D - 4 Auxiliary Mode ............................................................................................................................... K7 - 6
Program Functions: Programmable Ejector ............................................................................... K5D - 5
Program Functions: Program Loop ............................................................................................. K5D - 6 Maintenance ................................................................................................................................. K8 - 1
Program Functions: Repeat Cut Device ELTROTACT ............................................................... K5D - 7 Basic information about servicing and maintenance work ........................................................... K8 - 2
Program Examples with ELTROTACT ........................................................................................ K5D - 8 Index .............................................................................................................................................. K8 - 8
Determination of Remaining Measurement with ELTROTACT ................................................... K5D - 9
Repeat Block - Automatic Repetition .......................................................................................... K5D - 9
Program Functions: ET-Block with Absolute Positions ............................................................. K5D - 10
Program Functions: Program Parameters (XT) ........................................................................ K5D - 11

Menu Key: External Additional Functions (XT) ...................................................................... K5E - 1

External Additional Functions ...................................................................................................... K5E - 2
Storing of External Additional Functions with Entering of Cut Size ............................................ K5E - 2
Subsequent Storing / Erasing of External Additional Functions ................................................. K5E - 3
External Additional Functions: Optional Equipment "Gripper Loading System G"
(Autotrans MM) ............................................................................................................................ K5E - 4
External Additional Functions: Optional Equipment "Gripper Loading System GF"
(Autotrans M) ............................................................................................................................... K5E - 5
External Additional Functions: Optional Equipment "Turning Gripper" (Autoturn) ................... K5E - 10

Menu Key: Auxiliary Functions ................................................................................................ K5F - 1

Auxiliary Functions: Set/Delete Program Protection ................................................................... K5F - 2
Auxiliary Functions: Simulation without Cuts (XT) ...................................................................... K5F - 2
Auxiliary Functions: Cut and Record ........................................................................................... K5F - 3

E-3
 Control Panel 78 XT - 176 XT

Control panel POLAR 78 XT - 176 XT

On the 78 XT - 176 XT models, the operation is performed

via touch-screen terminal, i. e. a touch-sensitive 15" TFT
display.

7 8 9
4 5 6
1 2 3
C 0

Control panel POLAR 115 XT - 176 XT

with "special backgauge" options section (swivel
backgauge / tilting backgauge / Fixomat / hold-down
clamp at backgauge)

7 8 9
4 5 6
1 2 3
C 0

E-4
Control Panel 78 X - 176 X

Control panel POLAR 78 X - 176 X

The 78X - 176 X models are generally opera-

ted via the control console
D

7 8 9
4 5 6
1 2 3
C 0

E-5
 Operating Elements (X Models)
Automatic operation block Actions block
D

Insert; subsequent
Automatic ON 7 8 9 insertion of data
4 5 6
Automatic OFF Delete
1 2 3
Automaitc knife OFF C 0
Correction (of
Cursor block stored data)

Enter
Cursor keys
(right, left, up, down
center key: Backgauge keys Memory Read - Recall of calculator
Additional cursor motion - Backgauge movement:slow advance memory into input field
cursor in basic position) Backgauge movement:slow reverse
Calculator memory
Transfer key: transfer backgauge pos.
into input field
Numerical keypad
Selection of page via cursor keys (e. g.
Additional pushbutton for backgauge movement: in Program Directory)
upon simultaneous actuation of any of the two
7 8 9 Division backgauge pushbuttons: fast advance or return
movement of the backgauge
4 5 6 Multiplication
Basic menu and Additional menu block
1 2 3 Addition Menu-key "Additional Functions"
Basic menu "Program-Data" D Menu-key "External Additional Functions"
C 0 Subtraction
Menu-key "Auxiliary Functions"
Equal
Basic menu "Program-Information" i Menu-key "Program Functions"
Basic menu "Main menu"
Menu-key "Machine Parameters"
Decimal point
Basic menu "Program Directory" Menu-key "User Defined Aditional Functions"
Clear input field Program Selection

Step Selection

E-6
Special Function Moduls on Operating Panel (XT Models)
DNF - Modul (special backgauge) Correction - Modul
(Swivel backgauge, Tilting backgauge, Fixomat) (Distortion corr. / Cut correction)

.
Symbol for "Fixomat"

Symbol for "Swivel backgauge"

Rotary knob "Label correction"
Symbol for "Tilting backgauge"

1 2 3 Function keys "Tilting Backgauge"

1 Tilting backgauge "Undercut"
2 Tilting backgauge "0 - position"
3 Tilting backgauge "Overcut" Rotary knob "Distorsion correction"

Function keys "Swivel Backgauge"

1 Swivel backgauge "Angle correction left"
2 Swivel backgauge "0 - position"
3 Swivel backgauge "Angle correction right"

Double function keys for Holding-down

function at the backgauge (upper half) and Fixomat (lower
half):
Assignment:
1 Holding-down clamp "Final position" / Fixomat "sidemark 8 9
7
guide"
4 5 6
2 Holding-down clamp "Resting position" / Fixomat "0 position"
3 Holding-down clamp "Working position" Fixomat "frontmark 1 2 3
guide" C 0

E-7
 Operating Elements (XT Models)
Touch-screen terminal (78 XT - 176 XT models) PowerMonitor (Option) Scroll bar

Tooltip

EasyMode

Insert; subsequent
insertion of data

Basic Menu Correction (of stored

"Program-Data" data)

Basic Menu Menu Key Menu Key Delete

"Program-Information" "Ext. Add. Functions" "User Defined
or "Automatic Off"* Add. Functions" Transfer key: transfer
Basic Menu backgauge pos. into
"Main Menu" input field

Basic Menu Memory Read

"Program Directory" Trigger Menu Key Menu Key
function "Auxiliary Functions" "Machine Parameters"
Memory

Superimpose
numerical keypad
on/off

Menu Key Menu Key Step Program Input Mode Return

"Add. Functions" "Program-Functions" or Selection Selection On/Off
or "Automatic On"* "Automatic Knife Off"*
* if "Input Mode Off"

E-8
Touch-Screen Calibration (XT Models)

Before calibrating the touch screen, active the adjusting mode. Touch-Screen

Please note!
Do not use any pointed object for calibrating the touch screen, because you
risk to damage the touch screen in this way.

Touch-Screen Calibration

1. Press "Additional pushbutton for backgauge movement (high-

Fig. 1
speed)" and key "Addition" on numerical keypad simultane-
ously (!).

< The display shows the calibration mode, fig.1 >

2. Touch the center of the red cross (fig. 1).

< When the red cross is identified, this is confirmed by a signal tone and the
red-colored cross goes from the left bottom to the right top (Fig. 2) >

3. Touch the center of the red-colored cross (fig. 2).

Fig. 2
< The identification of the red-colored cross is confirmed by a signal tone >

4. The calibration is finished. The display returns to the Program-Data menu

(Fig.3).

Fig. 3

E-9
 Operation / Functionality of the Display

Control panel 115 XT - 176 XT: special backgauges swivel backgauge /

Touch-screen terminal (78 XT - 176 XT models) tilting backgauge / Fixomat and hold-down clamp in front of backgauge

On the 78 XT - 176 XT models, the operation is performed via touch-screen

terminal, i. e. a touch-sensitive 15" TFT display.

Special features of the touch-screen terminal:

• Menu-driven overlay of function / menu touch keys, in the side and bottom 7 8 9
toolbars of the display. (The system displays only those
4 5 6
function and menu keys which are required for editing or running the
1 2 3
programs).
C 0

• A touch of the finger will trigger or select the respective function

• The activated touch keys are highlighted and shown in a different color.

• The activation sections in a menu mask, e. g. lines in the program data

menu, menu register cards etc. are not limited to the corresponding step
Special backgauges: swivel backgauge /
number / selection number. The whole line is touch-sensitive.
tilting backgauge / Fixomat and hold-down
clamp in front of backgauge
• The step cursor in the "Program Data" menu remains always
positioned in the center of the display. When a different step number is activa-
Distortion and cut correction adjustment
ted, the program steps will be shifted (except: end of program). This ensures
that the program remains more clearly arranged.
Manual backgauge movement
• Scroll bar / page keys / cursor functions on the display, touch-sensitive. To
"scroll" to the following pages in a selected menu: Control consoles in the left / right light-barrier housing for the operation of:
Autotrim front table functions, stack lift on the left / right, retractable side gauge
• "Return" touch key: to return to the previously selected menu. left / right, Transomat B.

The only exceptions are the following functions which can be activated from the
corresponding control consoles by pressing the keys as usually.

• Distortion and cut correction

• Manual backgauge movement
• Numerical keypad (can be superimposed on the touch-screen terminal, see
page E-10)
• Special backgauge functions "swivel / tilting / Fixomat backgauges" (optional)
• Hold-down clamp at the backgauge (optional)

E-10
Operation / Functionality of the Display

• Fixed stack lifts (optional) right-hand tool bar

• Retractable side gauge(s) (optional)
• Manual Autotrim functions (optional)
• Gripper-loading systems (optional)

Touch Keys (touch-sensitive keys on the display)

Before a program can be input or edited, press the touch key "Input mode on/
off". After that, the system shows all of the menu and function keys on the display
which are available to input a program. For running the programs, only the 7 8 9

required function and menu keys are superimposed on the screen. For this 4 5 6
purpose, the function "Input on / off" must be turned off. The touch keys in the 1 2 3
bottom and the right-hand tool bars will change. C 0

Help Function (Tooltip)

All of the XT models are provided with a Tooltip which indicates the functions of all
of the touch keys. To display the Tooltip:
1. Press the touch key "TOOLTIP" in the right-hand tool bar
2. Press the desired touch key < the balloon help is superimposed > bottom tool bar
To deactivate the tooltip:
Press the "TOOLTIP" touch key again or actuate the activated touch key two times.
"Tooltip"
touch key
Scroll bar / cursor keys / page keys / "Return" key

Depending on the menu mask, the display may offer the following items rather than
usual cursor keys on the control console:
- a touch-sensitive scroll bar, for instance to scroll through the programs
- touch-sensitive cursor keys to scroll through the menus
- touch-sensitive page keys, which allow to rapidly "page through" the menus (e. g. Num. keypad,
program directory) superimposed
- a "Return" function key to jump back to the previously selected menu page.

Numerical keypad "Superimpose

numerical
keypad on/off"
The numerical keypad can be superimposed additionally on the touch-screen
terminal. It has the same keyboard elements / functions as the usual numerical
keypad on the control console. To do so, press the touch key "Superimpose Num.
Keypad On/Off" or simply touch the input section for superimposing On/Off. input section "Return" touch key

E-11
 Operation / Functionality of the Display

Special feature: The superimposed keypad can be arranged on the display Example: "Program information" menu
according to the operator’s wish. To do this ...
- touch the red pin on the keyboard (arrow symbol is shown)
- touch any desired area on the display

Input of plain text

On XT models, the plain text is input via a superimposed alphabetic keypad in

the top right area of the display. The superimposed keypad is shown in a
minimized form. By touching the superimposed image, the alphabetic keypad is
maximized and positioned in the center of the display. The text is input in a
special input line of the alphabetic keypad (and at the same time in the input
section of the menu). By pressing the "Enter" button of the superimposed
alphabetic keypad the text is transferred to the program / menu.
The mode of the alphabetic keypad can be switched from alphabetic display to
keyboard display.
On X models, the plain text is input via soft keys. The keypad is activated by
pressing the "Multiplication" button on the numerical keypad. To input the text,
every single letter has to be selected with the cursor, and then taken over to the
input section by pressing the "Home" cursor button.

"Trigger function" touch key in the input section of the menu

To trigger the various functions (such as positioning, programming etc.) the

"trigger function" touch key has been situated in the input section. This allows to
trigger the function immediately from the touch-screen terminal. The symbol
shown on the touch key will change according to its functionality (e. g. Enter,
Positioning, Equals).

Networking (optional)

All of the models with touch-screen terminals can be equipped with interface
cards and in this way enabled for networking. Interlinking is made via an
Ethernet interface.
Optional software provides the data transmission of cutting programs.
Optional software available: Select mode Delete Enter
• Compucut (cutting program generation)
• Direct data transfer from the prepress (CIP-3)
• Remote diagnosis (Remote Control) "Trigger function" Alphabetic keypad
• Connection to a "Wireless LAN" (mobile network (via Ethernet interface)) touch key minimize

E-12
Operation / Functionality of the Display

EasyMode (XT Models)

EasyMode is a streamlined programming mode for setting up programs on XT PowerMonitor (Option) EasyMode
machines.
EasyMode allows to show all of the pictographs of the programmable additional
functions in the Data Menu program in order to ensure an efficient program
generation. The feature is described in detail under "Additional functions", on
page K5C - 10.

PowerMonitor (Optional on XT with OptiKnife feature)

The PowerMonitor feature checks the load which the machine is bearing under
a cut.
The degree of loading is represented graphically, in the form of a colored dyna-
mic load display in the program header of the Program Data menu. The loading
display is divided into three loading zones, shown in the colors: green, yellow and
red.

The green area indicates a normal load onto the machine during the cut.

Yellow means that the load onto the machine is increased, but still within a
tolerable range.

Red means that the machine is put under a high load.

In this case, you should immediately examine the origin of this load, in order to
prevent the machine from being damaged.
Check in particular the following items in order to find the cause of the problem:

Possible cause Remedy

Type of material being cut Check the type of material being cut; if
necessary, contact the Polar Service Dept.
Feeding height Reduce the feeding height
Feeding width Reduce the feeding width
Blunt knife Change the knife

E-13
 Operation / Functionality of the Display

CountMonitor (Optional on X and XT Models)

The CountMonitor is a modified kind of progress control or performance measu-

rement and serves to determine the number of sheets or feeding height of the
material being cut. The relevant values are determined by the pressure clamp.
The feature is described in detail in the "Auxiliary functions" menu, page K5F - 8.

Basic Models 78 X - 176 X Control panel POLAR 78X - 176X

The basic models 78 X - 176 X are equipped with a standard 15" TFT display.
The machine is conventionally operated via controls on the control console, i. e.
the step numbers, register cards, menu items are selected with the cursor keys
D
on the control console or by entering the corresponding register card / menu
item number on the numerical keypad. i

7 8 9
4 5 6
1 2 3
C 0

E-14
Explanation of Pictographs on the Display

Pre-clamping time Lay guide II Key equals Clamp fixing

Clamping grade parameters Additional functions Key Program Selection Taste Cursor Up/Down

External additional functions Program functions Key Step selection Help

Feed mark Rear table air On Key Program Data display Key Cursor Home

Programmable ejector Auxiliary functions Key Program Information Numerical keypad

Servo ramp increase Autotrim front table lowering Key Function Survey Hand wheel

Servo ramp decrease Paper sizes Key Program Directory Clamping grade 0 - 9

Fixomat ON front margin Material-Correction Automatic knife active Backgauge advance

Fixomat ON side margin Camera ON r-h side Nominal position Backgauge reverse

Page back Camera ON l-h side Measuring unit Cut buttons

Tilting backgauge Layer counting Function comments Ext. add. function aktive upon start-up

Swivel backgauge Clamping without cut active Material correction Ext. add. function aktive upon stop

Holding-down clamp active/passive Key Enter Check cut Marking during cutting

Holding-down clamp active Key Correction LS - Label size Difference formation

Autotrim front table lifting Key Delete LQ - Label quantity Key Actual to nominal position

Side gauge /both downward Key Insert TC - Total cuts Set program protection/On

Side gauge /left downward Key Memory Keys Cursor right/left Backgauge advance slow

Automatic knife prepared Key Memory Read Fix clamp Autotrim

Lay guide I Positioning Key Cursor Up/Down Clamping without cutting

E-15
 Explanation of Pictographs on the Display

Automatic ejector off Side gauge, general Correct basic position Parameterliste/Copy

Complete air off Cutting optimization or clamp Correct actual position PMS Card
optimization
Complete air on Press material Block programming: label incl. margin
Cutting optim./smooth preclamping
Front table air on Material-Correktion: Minus Block program.: label without margin
Cutting optim./high-speed cutting
Clamping grade 0 - 9/sensor Clamp lifting after knife lower dead point Block programming: optimization stage
Cutting optim./clamp light barrier/
Knife change elevating time Comment selection Block programming:utilization

Turn cw by 90° Comment input Main drive unit not ready

Program loop

Turn ccw by 90° Simulation Eltrotact Total cut Press pedal

Function survey/memory/copy

Turn by 180° Program protection seting/delete Autotrim, last margin cut

Function survey/language

Put aside Please wait Autotrim, last label

Knife thickness correction list

Feed Down Load Card Autotrim, adjusting station

AT/hold-down blast air ON

Key figure 1 (num. keyboard) Clamping without cut/clamping time Order

Function survey/block programming

Clear Clear input or page back Delete step

Function survey/ pre-adjust functions

Service menu Backgauge keys, general Select step

Parameter list

Call service Table of clamping grades Correct/insert Additional functions

Function survey/production report

Error Backgauge speed/grade Delete Additional functions

Fixomat, general

Clamping grade/sensors Smooth braking to stop Look for order

Swivel backgauge, general

Smooth braking to stop Yes/No Autotrim Blowing air, On Select program number
Tilting backgauge, general

Reference run Autotrim Blowing air Start/End Delete program number

Holding down clamp, general

E-16
Explanation of Pictographs on the Display

Under cut Edge trim (block programming) Autotrim table, close

Auxiliary operation Graphic Off Autotrim, pusher left

Plus/Positve sign Material size Autotrim, pusher right

Minus/negative sign Knife lower dead point/time Lateral positioner right

Simulation of cutting sequence Electronical handwheel Trim-out positioner

Warning On: skip cutting CP-Data program filter Automatic ON

in automatic op.: corr. of nom. position Graphic On Automatic OFF / manual

Warning Off: skip cutting Front table air suction

Automatic knife OFF

Comments Maintenance cut counter

User defined additional functions

Printing Data Control / operation time

Retractable side gauge right
Change contrast of display Data Control / adjusting time

Knob distorsion correction Data Control / other times

Knob label correction Data Control / aux. time

PMS Card machine data Data Control / break time

Cursorsubstitution left/right Alpha keyboard On/Off

Align material without Autotrim Alpha keyboard, fast searching

Original sheet size (block program.) Preset cut counter

Label size (block programming) Autotrim, align material

Data Control Hold. down clamp in front of the knife

E-17
 Chapter survey Page

1.0 Technical Data/Machine Layout/Transport and Installation of Machine/

Safety relevant machine elements .................................................................................. K1 - 1

2.0 Safety.............................................................................................................................. K2 - 1

3.0 Start-Up .......................................................................................................................... K3 - 1

4.0 Manual Operation ........................................................................................................... K4 - 1

5.0 Automatic Operation .................................................................................................... K5A - 1

6.0 Knife Change .................................................................................................................. K6 - 1

7.0 Malfunctions/Breakdowns ............................................................................................... K7 - 1

8.0 Maintenance/Index ......................................................................................................... K8 - 1

E-18
Introduction

High-Speed Cutter POLAR form a part of the wide range of products manufactured by the POLAR company.
Decades of experience in constructing high-speed cutting machines and peripheral equipment, together with state-of-the-art engineering and manufacturing procedures,
careful testing and highest quality standards ensure the reliability and performance of your POLAR machine.

Please pay special attention to the following information:

• The section on "Safety” in the operating instructions!

• The operating instructions are not meant as an instruction for repair. Such work should be carried out by POLAR service, exclusively.

• Use only original POLAR spare parts; indicate type and machine number in your requests.

• Illustrations in the operating instructions / spare parts catalogue may deviate from the real design. Nevertheless, the information given is not altered by this.

• The use of the aids mentioned in the operting instructions, such as oils, greases, cleansing agents etc. refers to the preparation date of these instructions.

The complete Technical Documentation should always be kept near the machine.
We recommend to read these operating instructions carefully prior to commissioning the machine, because we shall not be liable for any damage or breakdown resulting
from any nonobservance of these operating instructions.

Copyright

All rights reserved for this document. No part of it may be duplicated or brought to the notice of other people in any form without our express consent.
Any violation engages to damages.

The Operating Instructions must be stored for future use!

E-19
E-20
 Technical Data / Machine Layout / Transport and Installation of the Machine /
1.0 Safety Relevant Machine Elements / Description of the Machine

K1-1
 1.0 Technical Data / Machine Layout / Transport and Installation of the Machine / Safety Relevant Machine Elements
Machine Layout
1.1
The illustration shows machine type 92X
19 1
1 Main switch
2
1.1 Control voltage ON/OFF 17 POLAR 92 X 5
2 Control panel with display 7 8
17
3 Hand wheel / fine adjustment of cut size 6
15
4 Cut buttons 18 14
5 Clamping pressure adjustment (models 78 - 137) 4 4
6 Clamp 10 3
7 Knife bar with knife 13
16
8 Switch for cutting line indicator/ Table lamp
9 Backgauge with rakes 12
10 Cutting stick / Cutting line 11
11 Pedal
21 Front side (Operating side)
12 Circuit breakers / Fuses (under the guard - front side)
Rear side
13 Clutch guard for main drive unit
14 Lid of clutch guard
15 Access hole lid 9
16 Air table switch
17 Light barrier
18 Short left-hand gauge
19 Flap for knife change
20 Gearbox covering
23
21 Guard - front side 20
22 Guard - rear side
23 Blower 22

K1-2
1.0 Technical Data / Machine Layout / Transport and Installation of the Machine / Safety Relevant Machine Elements
Plan
A V

B
X
C
500 500 500

F
78 92 115 137 155 176
D mm/inch mm/inch mm/inch mm/inch mm/inch mm/inch
E
Weight at position "1":
4 S
4 A 1980 / 77,95 2120 / 83,46 2712 / 106,77 2932 / 115,43 3410 / 134,25 3620 / 142,51
B 990 / 38,97 1060 / 41,73 1325 / 52,16 1435 / 56,49 1778 / 70 1883 / 74,13

3 3 78 4270 N C
D
329 / 12,95
661/26,02
350 / 13,77
710 / 27,95
344 / 13,54
981 / 38,62
344 / 13,54
1091 / 42,95
653 / 25,70
1125 / 44,29
653 / 25,70
1230 / 48,42
92 6870 N
115 10000 N E 1438/56,61 1630 / 64,17 2151 / 84,68 2363 / 93,03 2540 / 100 2750 / 108,26
137 13730 N F - 120 / 4,72 200 / 7,87 200 / 7,87 200 / 7,87 200 / 7,87
155 16480 N G 780 / 30,70 920 / 36,22 1150 / 45,27 1370 / 53,93 1550 / 61,02 1760 / 69,29
U 176 17660 N H 600 / 23,62 600 / 23,62 750 / 29,52 750 / 29,52 1003 / 39,48 1003 / 39,48
M I - 1267 / 49,88 1653 / 65,07 1873 / 73,74 2001 / 78,77 2211 / 87,04
M Q Weight at position "2": J - 570 / 22,44 821 / 32,32 931 / 36,65 965 / 37,99 1070 / 42,12
T
L K 695 / 27,36 635 / 25 715 / 28,14 730 / 28,74 750 / 29,52 750 / 29,52
L 940 / 37 750 / 29,52 1020 / 40,15 1110 / 43,70 1160 / 45,66 980 / 38,58
78 6620 N
M - 600 / 23,62 650 / 25,59 650 / 25,59 650 / 25,59 650 / 25,59
P 92 8593 N
M R 115 15890 N N - 300 / 11,81 260 / 10,23 260 / 1010,23 260 / 1010,23 260 / 1010,23
N 137 20410 N O - 300 / 11,81 400 / 15,74 400 / 15,74 400 / 15,74 400 / 15,74
K 155 23840 N P - 255 / 10,03 360 / 14,17 360 / 14,17 360 / 14,17 360 / 14,17
176 26450 N Q - - - - 2355 / 92,71
R - 104,5 / 4,11 137,5 / 5,41 137,5 / 5,41 172,5 / 6,79 172,5 / 6,79
Weight at position "3/4": S 580 / 22,83 600 / 23,62 700 / 27,55 700 / 27,55 1090 / 42,91 1090 / 42,91
T 290 / 11,41 300 / 11,81 350 / 13,77 350 / 13,77 545 / 21,45 545 / 21,45
J U 200 / 7,87 400 / 15,74 400 / 15,74 400 / 15,74 400 / 15,74 400 / 15,74
78 930 N
V 2020 / 79,52 2185 / 86,02 2563 / 100,90 2845 / 112 2981 / 117,36 3808 / 149,92
92 1620 N
1 I O 2 115 2750 N
W - - - - - -
137 3140 N X 698 / 27,48 698 / 27,48 718 / 28,26 733 / 28,85 753 / 29,64 756 / 29,76
155 4120 N Y 900 / 35,43 900 / 35,43 900 / 35,43 900 / 35,43 900 / 35,43 900 / 35,43
H G H
176 1470/5890 N Z 1574 / 61,96 1595 / 62,80 1710 / 67,32 1710 / 67,32 1745 / 68,70 1745 / 68,70

K1-3
 1.0 Technical Data / Machine Layout / Transport and Installation of the Machine / Safety Relevant Machine Elements
Transport and Installation of the Machine

After Unloading
• Remove all packing and wrapping material
• Check machine and accessories for damages
• Check for missing parts

Have the machine installed by POLAR service personnel, exclusively! In Case of Complaints
The installation of the machine requires special skills which can be guaran- Immediately send written note to:
teed only by especially trained experts of POLAR agencies. • Railway or shipping company
Arbitrary working on the machine may damage the machine itself or other • Insurance company
material property of the user or cause accidents endangering life and limb • POLAR MOHR / Agency
of the staff.

The machine must be unpacked, moved, transferred and installed by autho- Place of Installation
rized POLAR Service Technicians only. Dangers might arise from the
machine itself or from its packing if it is unpacked, moved, transferred or The location must meet the following requirements:
installed with unsuitable devices.
• Vibration free location
While the machine is unpacked, moved, transferred and installed, no other • Even concrete flooring, concrete property class min. (N/mm²) according to
persons must be present in the range of the machine or its packing. eurocode 2: C20/25 or according to DIN 1045: B 25
• Observe carrying capacity!
The POLAR Service Technician must also take care that no unauthorized • Avoid possible accidents of operator by uneven flooring
persons work at the machine, its packing or the installation equipment. • Adhere to minimum distance from buildings or peripheral equipment (see
plan).

After the Installation of the Machine

1. Remove anti-rust paint (agent: kerosene, gasoline) from the machine on the
site of installation
Note: Do not use any sharp tools to remove anti-rust paint!
2. Clean plastic covers only with plastic cleansing agent
3. Assemble machine
4. Final check according to check list
5. Have handover signed

K1-4
1.0 Technical Data / Machine Layout / Transport and Installation of the Machine / Safety Relevant Machine Elements
Power Supply Type Plates

The machine is to be connected by an authorized electrician, only! The machine designation including
Connect machine according to diagram!
• manufacturer‘s address
Energy supply is made from the rear of the machine. • model
Power supply is located within the connection box. • machine number
• electric. equipment
Attention! • year of construction
• When the system is operated with residual current breaker, use a residu-
al current breaker (>30 mA) for each machine! is indicated on the machine type plate.
• All the cables marked with a symbol, as well as any cables with A distinction is made between type plates for Non-EC countries and those for EC
orange sheath are still alive even if the main switch has been shut off. countries.

Type plate for Non-EC countries:

POLAR 92 X Adolf Mohr

Maschinenfabrik
65719 Hofheim/Ts
Germany

Model

Mach. No.

/SL AC V Hz A

Power supply
Type plate for EC countries:

Adolf Mohr
Maschinenfabrik
65719 Hofheim/Ts
Germany

Modell

Masch. Nr. Baujahr

/SL AC V Hz A
Energy lead wire

K1-5
 1.0 Technical Data / Machine Layout / Transport and Installation of the Machine / Safety Relevant Machine Elements
Safety Relevant Machine Elements

6 7 14

1
8
POLAR 92 X

2 2

4 4
12
12
13

11 16 15 5 16 10

K1-6
1.0 Technical Data / Machine Layout / Transport and Installation of the Machine / Safety Relevant Machine Elements
Safety Relevant Machine Elements

1 Emergency-stop switch (main switch) 9 Protection in case of con-rod fracture by shear bolt (predetermined brea-
king point)
2 Light barrier (20-channel) Max. breaking load Type 78 4,6 t
Object detection capability: 25 mm Type 92: 7.6 t
Min. distance of light barrier: Total reaction time of system: Type 115: 13 t
Type 137: 15 t
Type 78 336 mm < 121 ms Type 155/176: 17 t
Type 92 345 mm < 125 ms
Type 115 372 mm < 140 ms 10 Safety catch for clamp return spring in case of spring fracture
Type 137 372 mm < 140 ms
Type 155 392 mm < 150 ms 11 Guard of backgauge drive unit
Type 176 392 mm < 150 ms
12 Guard of main drive unit
Caution! Please note !
The front table of the cutting machine must be sufficiently extended 13 Clutch-brake combination with braking efect in case of energy breakdown
to the sides with the appropriate peripheral tables (such as side
tables, air conveyor units) to guarantee that the area beneath the light 14 Menu-driven knife change per display
barrier housing and the plexiglass guard against manual access is
perfectly covered by a sufficiently large table the same height as the 15 Complete table slit covering (in front of and behind the backgauge)
cutting machine front table.
16 Warning plate for electrical operating area (high-voltage flash)
This area may only be opened by authorized staff!
3 Safety latch for knife bar (mechanical lock against lowering of knife bar)

4 Two-handed cutting release with simultaneity control and anti-repeat circuit Safety Auxiliary Tools

5 Electronics: Angle for jogging the cutting material

- Failsafe control by multiple self-diagnostics
- Machine self-diagnostics with error message
Working Area of Operating Personnel
6 Guard to prevent reaching under the clamp bar
Working area is the complete front side (operating side) of the machine.
7 Rear-table guard, fixed or tiltable

8 Safety pressure for lowering the clamp by means of a pedal:

Types 78, 92, 115, 137, 155: max. 300 N
Type 176: max. 500 N

K1-7
 1.0 Technical Data / Machine Layout / Transport and Installation of the Machine / Safety Relevant Machine Elements
Safety Signs (for U.S. and CAN. specifications only)

Accident prevention warning labels at POLAR cutters Placement of the warning labels

Placement of the warning label Label 1 (2x): Label 2 (2x): Label 3 (2x):

Warning labels are of little value if the foreseeable user cannot see them at the Location: Location: Location:
appropriate time, i.e., before he or she encounters the hazard. Labels, therefore, At main drive guard and At the lower front of the At the front and the rear
should be placed near the hazard and in such a position that the worker will see backgauge drive guard. cutter. of the cutter.
and be able to read them before encountering the hazard. POLAR order no.: POLAR order no.: POLAR order no.:
281267 281266 281268
Durability

Accident prevention warning labels should be kept sufficiently durable to remain

easily readable at an appropriate distance for a reasonable life.

K1-8
1.0 Technical Data / Machine Layout / Transport and Installation of the Machine / Safety Relevant Machine Elements
Safety Signs

Safety Signs / Warning Signs Prohibitive signs

In order to ensure maximum safety the machine / system is provided with safety No admittance to unauthorized persons
signs. Safety signs are either standardized safety signs warning of risks or (e. g. areas which are secured by shielding or safety
danger, or warning signs alerting the operating or service staff of devices (guard rail with a door, possibly secured by an
- any forbidden actions at the machine / system, emergency stop function)). Access to danger zone is
and/or only admitted to authorized personnel!
- informing about any load limits, such as the max. carrying capacity of the
machine and/or its load carrying unit. Rear table area of cutting machine
While the machine is in operation, it is forbidden to
Safety signs must be durable and have to be kept in a perfectly visible condition. - manually reach into the rear table
Warning signs ought to be visible in good time even from a great distance. - stay on or under the rear table.
The prohibitive sign is positioned on both sides of the
The machine /system may be provided with the following safety or warning rear table.
signs on various components of the machine:

Machine specific warning signs (examples)

Warning: Dangerous voltage Warning sign: “Load carrying unit”*

(e. g. electrical connector boxes, control boxes/ It is strictly forbidden to
control cabinets of machine control systems) - step onto the load carrying unit* and the load.
- sit on the load carrying unit and the load
- take shelter under the load carrying unit and the
load (neither persons nor objects!)
- ride on the load carrying unit* and the load
Warning: Laser irradiation
(laser light barriers)

“Load capacity” information sign

Indication of max. load of machine and its load
carrying unit*
Warning: Risk of hand injuries (e. g. lifts, transport facilities)
(e. g. grippers, air-removing roller at automatic
jogger, automatic gauges)

* load carrying units = lift forks, lift platforms, pallets, etc.

K1-9
 1.0 Technical Data / Machine Layout / Transport and Installation of the Machine / Safety Relevant Machine Elements
Technical Data

Permissible Environmental and Operating Conditions • Observe the procedures described in case of malfunctions and the
maintenance intervals indicated.
Operate the machine in closed areas, exclusively!

Air humidity: 35% - 95% (non condensing) Residual Risk

Ambient air temperature: +5° C - +40° C
In spite of the safety measures provided by construction there remains a residual
risk when operating the machine.
Hydraulic Data This residual risk mainly concerns the danger of contusions and cuts during
clamping, cutting or knife change as well as handling the cutting material in
Hydraulic operating pressure: 16 - 150 bars! general, if the necessary care is neglected.
The installation is designed for a maximum permissible pressure of 200 bars. The parts especially affected are the upper extremities of the operating staff -
especially their arms and hands.

Particular attention must be paid when a knife changing is performed. The knife
Safety Precautions
may only be changed by personnel especially instructed for this purpose!
Always use the knife guard when changing or transporting the knife outside the
• Minimum age of operating staff: 18 years!
knife case!
Please make sure to verify the effectiveness of the safety installations before
• Before starting any work at the machine - read safety section of manual!
every shift and after every knife change. It is recommended to record the test
results!
• During the working process no other persons must enter the working
area or interfere with the process

• Use the angle included in the scope of supply for positioning the cutting Safety Inspection
material
Under the current terms of the EU law, which has been implemented in Germany
• Knife change may only be carried out by personnel especially in the form of the Betriebssicherheitsverordnung (industrial safety regulations),
trained for this purpose the user has to perform a risk assessment regarding this machine, and to define
the scope and periods of inspection on the basis of its operating conditions.
• Utmost care must be taken when handling the knife!! Based on decades of experience POLAR has developed an adequate safety
Always deposit or transport the knife in the knife case. conception which meets all of the demands for a safe operation of this machine.
For more information on this topic, please contact your agency in charge.
• Use only undamaged and sharp knives!

• During the cutting no tool or objects - such as e.g. T-wrench must be

on the machine table in order to prevent them from reaching
unintentionally under the clamp and/or knife during the cutting process.
There is a high risk of injuries due to little parts of the knife edge coming
off in splinters.

K1-10
1.0 Technical Data / Machine Layout / Transport and Installation of the Machine / Safety Relevant Machine Elements

Technical Data
Polar 78 Polar 92 Polar 115 Polar 137 Polar 155 Polar 176

Cutting width 78 cm / 30.7087" 92 cm / 36.2205" 115 cm / 45.2756" 137 cm / 53.9370" 155 cm / 61.0236" 176 cm / 69.2913"

Feeding height max. (without false clamp) 12 cm / 4.7244" 13 cm / 5.1181" 16,5 cm / 6 1/2" 16,5 cm / 6.4961" 16,5 cm / 6.4961" 16,5 cm / 6.4961"

Feeding depth 78 cm / 30.7087" 92 cm / 36.2205" 115 cm / 45.2756" 145 cm / 5.0866" 155 cm / 61.0236" 225 cm / 88.5826"

Power requirement (main drive) 3,45 kW / 4.75 H.P. 4,45 kW / 6.1 H.P. 5,7 kW / 7.85 H.P. 6,6 kW / 9.1 H.P. 8,2 kW / 11.3 H.P. 8,2 kW / 11.3 H.P.

Total weight net, (without special equipment) 1350 kg / 2976 lbs 1920 kg / 4233 lbs 3230 kg / 7121 lbs 4150 kg / 9149 lbs 4950 kg / 10913 lbs 6200 kg / 13671 lbs

Width without side table 158 cm / 62.2047" 177 cm / 69.6850" 236 cm / 92.9134" 258 cm / 101.5748" 275 cm / 108.2677" 296 cm / 116.5354"
with side table 198 cm / 77.9527" 212 cm / 83.4645" 265 cm / 104.3307" 288 cm / 113.3858" 355 cm / 139.7637" 376 cm / 148.0315"

Depth 202 cm / 79.5276" 223 cm / 87.7953" 256 cm / 100.7874" 284 cm / 111.8110" 298 cm / 117.3228" 381 cm / 150,00"

Height 157 cm / 61.8110" 159 cm / 62.5984" 171 cm / 67.3228" 171 cm / 67.3228" 174 cm / 68.5039" 174 cm / 68.5039"

Front table length 69,5 cm / 27.3622" 69,5 cm / 27.3622" 71,5 cm / 28.1496" 73 cm / 28.7402" 75 cm / 29.5276" 75 cm / 29.5276"

Table height 90 cm / 35.4331" 90 cm / 35.4331" 90 cm / 35.4331" 90 cm / 35.4331" 90 cm / 35.4331" 90 cm / 35.4331"

Clamp pressure min. 150 daN / 331 lbs 150 daN / 331 lbs 150 daN / 331 lbs 150 daN / 331 lbs 150 daN / 331 lbs 150 daN / 331 lbs
max. 3000 daN / 6614 lbs 3500 daN / 7716 lbs 4500 daN /9921 lbs 5500 daN / 12125 lbs 6000 daN / 13228 lbs 7000 daN / 15432 lbs

Knife thickness 11,75 mm / 0.4606" 11,75 mm / 0.4606" 13,75 mm / 0.5413" 13,75 mm / 0.5413" 13,75 mm / 0.5413" 13,75 mm / 0.5413"

Knife grinding reserve (HSS 18 knife), max. 2,5 cm / 0.9843" 3 cm / 1.1811" 5 cm / 1.9685" 5 cm / 1.9685" 5 cm / 1.9685" 5 cm / 1.9685"

Smallest cut, without false clamp, min. 2 cm / 0.7874" 2,5 cm / 0.9843" 2,5 cm / 0.9843" 2,5 cm / 0.9843" 3,5 cm / 1.3780" 3,5 cm / 1.3780"
with false clamp, min. 7 cm / 2.7559" 9 cm / 3.5433" 9,5 cm* / 3.7402" 9,5 cm* / 3.7402" 12 cm / 4.7244" 12 cm / 47244"

Smallest cut, manual without false clamp 1,5 cm / 0.5906" 1,8 cm / 0.7087" 2 cm / 0.7874" 2 cm / 0.7874" 3 cm / 1.1811" 3 cm / 1.1811"

Backgauge speed 0 - 20 cm/sec. 0 - 20 cm/sec. 0 - 30 cm/sec. 0 - 30 cm/sec. 0 - 30 cm/sec 0 - 160 cm/sec

Static floor load 626 daN/m² / 700 daN/m² / 755 daN/m² / 731 daN/m² / 784 daN/m² / 780 daN/m² /
131 lbs/sqft 146 lbs/sqft 158 lbs/sqft 153 lbs/sqft 164 lbs/sqft 163 lbs/sqft

Specific surface pressure 1,7 daN/cm² / 1,8 daN/cm² / 1,7 daN/cm² / 1,9 daN/cm² / 2,5 daN/cm² / 2,8 daN/cm² /
24 lbs/sqin 26 lbs/sqin 25 lbs/sqin 27 lbs/sqin 36 lbs/sqin 40 lbs/sqin

Dynamic surcharge 20% 20% 20% 20% 20% 20%

Supply voltage 200 - 240V

Fusing 20A 20A 30A 30A 35A 35A

Supply voltage 360 - 420V

Fusing 16A 16A 20A 25A 32A 32A

Attention! The wire cross section of the main power supply according to the countrys regulations. Same regulations according the plug connectors.

Noise emission.
Metering of noise level according to EN 13023, LpA (dB) 83 ( with 1152 cuts per hour (80% automatic operation))
Extraneous and room noise correction has been carried out. 77 ( with 300 cuts per hour (manual feeding))
* with Autotrim: 10 cm / 4"

K1-11
 1.0 Technical Data / Machine Layout / Transport and Installation of the Machine / Safety Relevant Machine Elements
EC-Conformity Declaration

EC - Conformity Declaration
according to EC Machine Directive (2006/42/EC, Annex II A)

The manufacturer

Adolf Mohr, Maschinenfabrik GmbH & Co. KG

65719 Hofheim/Ts., Hattersheimer Strasse 16 - 42

herby declares that the machine corresponds to:

• EC machine directive (2006/42/EC)

• EC EMC directive (2004/108/EC)

European standards:

EN 12100 - 1
EN 12100 - 2
EN 60204 part 1
EN 1010 part 1 - 3

K1-12
2.0 Safety

Any person on the user´s premises concerned with

the operation, maintenance and repair of the machine,
resp., is expected to have read and comprehended the
section on "Safety"

K2 - 1
 Foreword to the operating instructions Fundamental safety instructions Operating the machine within the limits of its designated use
also involves the instructions set out in the operating manual
These operating instructions are designed to familiarize the Warning and symbols and complying with the inspection and maintenance directi-
user with the machine/plant and its designated use. ves.
The following signs and designations are used in the manual
The instruction manual contains inportant information on to designate instructions of particular importance Organizational measures
how to operate the machine/plant safely, properly and most
efficiently. Observing these instructions helps to avoid Note/Attention: refers to special information on The operating instructions must always be at hand at the
danger, to reduce repair costs and downtimes and to how to use the machine/plant place of use of the machine/plant.
increase the reliability and life of the machine/plant. most efficiently
In addition to the operating instructions, observe and instruct
The instruction manual is to be supplemented by the the user in all other generally applicable legal and other
respective national rules and regulations for accident Symbol: refers to orders and prohibitions mandatory regulations relevant to accident prevention and
prevention and environmental protection. designed prevent injury or environmental protection.
extensive damage
The operating instructions must always be available where- These compulsory regulations may also deal with the
ver the machine/plant is in use. handling of hazardous substances, issuing and/or wearing
Basic operation and designated use of the machine/ of personal protective equipment, or traffic regulations.
These operating instructions must be read and applied by plant
any persons in charge of carrying out work with and on the The operating instructions must be supplemented by
machine/plant such as The machine/plant has been built in accordance with state- instructions covering the duties involved in supervising and
of-the-art standards and the recognized safety rules. notifying, special organizational features, such as job
- operation including setting up, troubleshooting in the Nevertheless, its use may constitute a risk to life and limb of organization, working sequences or the personnel entrusted
course of work, evacuation of production waste, care and the user or of third parties, or cause damage to the machine with the work.
disposal of fuels and consumables. and to other material property.
Personnel entrusted with work on the machine must have
- maintenance (servicing, inspection, repair) and/or The machine/plant must only be used in technically perfect read the operating instructions and in particular the chapter
condition in accordance with its designated use and the on safety before beginning work. Reading the instructions
- Transport instructions set out in the operating manual, and only by after work has begun is too late. This applies especially to
safety-conscious persons who are fully aware of the risks persons working only ocassionally on the machine, e. g.
In addition to the operating instructions and to the mandato- involved in operating the machine/plant. Any functional during setting up or maintenance.
ry rules and regulations for accident prevention and environ- disorders, especially those affecting the safety of the
mental protection in the country and place of use of the machine/plant, should therefore be rectified immediately. Check - at least from time to time - whether the personnel is
machine/plant, the generally recognized technical rules for carrying out the work in compliance with the operating
safe and proper working must also be observed. The machine is designed exclusively for cutting paper instructions and paying attention to risks and safety factors.
and cardboard.
Any other use, such as the cutting of metal foils or other For reasons of security, long hair must be tied back or
materials, or any further use beyond this is considered otherwise secured, garments must be close-fitting and no
contrary to its designated use. Other materials may be jewellery - such as rings - may be worn. Injury may result
processed only according to prior agreement with the from being caught up in the machinery or from rings cat-
manufacturer of the machine and after the written confir- ching on moving parts.
mation of the manufacturer.
The manufacturer/supplier cannot be held liable for any Use protective wherever required by equipment by the
damage resulting from a usage other than to the intended circumstances or by law.
purpose. The risk of such misuse lies entirely with the user.

K2 - 2
Observe all safety instructions and warnings attached to the regard to observing traffic regulations - giving the operator Never switch off or remove suction and ventilation devices
machine/plant. the authority to refuse instructions by third parties that are when the machine is in operation.
contrary to safety.
See to it that safety instructions and warnings attached to Special work in conjunction with utilization of the
the machine are always complete and perfectly legible. Do not allow persons to be trained or instructed or persons machine/plant and maintenance and repairs during
taking part in a general training course to work on or with the operation; disposal of parts and consumables
In the event of safety-relevant modifications or changes in machine/plant without being permanently supervised by an
the behaviour of the machine/plant during operation, stop experienced person. Observe the adjusting , maintenance and inspection activi-
the machine/plant immediately and report the malfunction to ties and intervals set out in the operating instructions,
the competent authority/person. Work on the electrical system and equipment of the machi- including information on the replacement of parts and
ne/plant must be carried out only by a skilled electrician or equipment. These activities may be executed by skilled
Never make any modifications, additions or conversions by instructed persons under the supervision and guidance of personnel only.
which might affect safety without the supplier´s approval. a skilled electrician and in accordance with electrical
This also applies to the installation and adjustment of safety engineering rules and regulations. Brief operating personnel before beginning special operati-
devices and valves as well as to welding work on load- ons and maintenance work, and appoint a person to super-
bearing elements. Work on the hydraulic system must be carried out only by vise the activities.
personnel with special knowledge and experience of In any work concerning the operation, conversion or adjust-
Spare parts must comply with then technical requirements hydraulic equipment. ment of the machine and its safety-oriented devices or any
specified by the manufacturer. Spare parts from original work related to maintenance, inspection and repair, always
equipment manufacturers can be relied to do so. Safety instructions governing specific operational observe the start-up and shut-down procedures set out in
phases the operating instructions and the information on mainten-
Never modify the software of programmable control sy- ance work.
stems. Standard operation
Avoid any operational mode that might prejudicial to safety. Ensure that the maintenance area is adequately secured.
Replace hydraulic hoses within stipulated and appropriate
intervals even if no safety-relevant defects have been Take the necessary precautions to ensure that the machine If the machine/plant is completely shut-down for mainte-
detected. is used only when in a safe and reliable state. nance and repair work, it must be secured against inadver-
tent starting by:
Adhere to prescribed intervals or those specified in the Operative machine only if all protective and safety-oriented - locking the principal control elements and removing
operating instructions for routine checks and inspections. devices, such as removable safety devices, emergency the ignition key and/or
shut-off equipment, sound-proofing elements and exhau- - attaching a warning sign to the main switch.
Selection and qualification of personnel - Basic respon- sters, are in place and fully functional.
sibilities Clean the machine, especially connections and threaded
Check the machine/plant at least once per working shift for unions, of any traces of oil or presevatives before carrying
Any work on and with the machine/plant must be executed obvious damage and defects. Report any changes (incl. out maintenance/repair. Never use aggressive detergents.
by reliable personnel only. Statutory minimum age limits changes in the machine´s working behaviour) to the compe- Use lint-free cleaning rags.
must be observed. tent organization/person immediately. If necessary, stop the
machine immediately and lock it. Always tighten any screwed connections that have been
Employ only trained or instructed staff and set out clearly the loosened during maintenance and repair.
individual responsibilities of the personnel for operation, set- In the event of malfunctions, stop the machine/plant imme-
up, maintenance and repair. diately and lock it. Have any defects rectified immediately. Any safety devices removed for set-up, maintenance or
repair purposes must be refitted and checked immediately
Make sure that only authorized personnel works on or with During start-up and shut-down procedures always watch the upon completion of the maintenance and repair work.
the machine. indicators in accordance with the operating instructions. Ensure that all consumables and replaced parts are dispo-
Before starting up or setting the machine/plant in motion, sed of safely and with minimum environmental impact.
Define the machine operator´s responsibilities - also with make sure that nobody is at risk.

K2 - 3
 Warning of special dangers The electrical equipment of machines/plants is to be inspec- Check all lines, hoses and screwed connections regularly
ted and checked at regular intervals. Defects such as loose for leaks and obvious damage. Repair damage immediately.
Any procedure impairing the safety at the machine must be connections or scorched cables must be rectified immedia- Splashed oil may cause injury and fire.
refrained from. In particular do not tely. Depressurize all systems sections and pressure pipes
(hydraulic system, compressed-air system.
- reach into the range of knife and clamp, use auxiliary Necessary work on live parts and elements must be carried
tools (e. g. material gauge) out only in the presence of a second person who can cut off Hydraulic and compressed-air lines must be laid and fitted
the power supply in case of danger by actuating the emer- properly. Ensure that no connections are interchanged. The
- reach into the range between clamp and cutting material gency shut-off or main power switch. Secure the working fittings, lenghts and quality of the hoses must comply with
gauge (backgauge with rake) on the machine rear table area with a red-and-white safety chain and a warning sign. the technical requirements.
Use insulated tools only.
- with Autotrim function:
entering the opened table crack to remove residual cuttings. Before starting work on high-voltage assemblies and after Oil, grease and other chemical substances
Only do that with the machine switched off. cutting out the power supply, the feeder cable must be
grounded and components, such as capacitors, short- When handling oil, grease and other chemical substances,
- at machines with attached and/or separately installed circuited with a grounding rod. observe the product-related safety regulations.
peripheral equipment with lifting/swivelling/moving and/or
clamping function: Be careful when handling hot consumables (risk of burning
do not enter or reach into the danger zone during movement Gas, dust, steam and smoke or scalding)
(provide guard rail)
Carry out welding , flame-cutting and grinding work on the
- The knife may only be changed by personnel especially machine/plant only if this has been expressly authorized, as
instructed for this purpose there may be a risk of explosion and fire.

Before carrying out welding, flame-cutting and grinding

Electrical energy operations, clean the machine/plant and its surroundings
from dust and other inflammable substances and make sure
Use only original fuses with the specified current rating. that the premises are adequately ventilated (risk of explosi-
Switch off the machine/plant immediately if trouble occurs in on).
the electrical system.
Observe any existing national regulations if work is to be
Work on the electrical system or equipment may only be carried out in narrow rooms.
carried out by a skilled electrician himself or by specially
instructed personnel under the control and supervision of
such electrician and in accordance with the applicable Hydraulic and pneumatic equipment
electrical engineering rules.
Work on hydraulic equipment may be carried out only by
If provided for in the regulations, the power supply to parts persons having special knowledge and experience in
of machines and plants, on which inspection, maintenance hydraulic systems.
and repair work is to be carried out must be cut off. Before
starting any work, check the de-energized parts for the The pneumatic equipment at the machine must only be
presence of power and ground or short-circuit them in connected to plant compressed-air supply system secured
addition to insulating adjacent live parts and elements. against overpressure.

K2 - 4
3.0 Start - Up

Attention!
Prior to any commissioning and any change of shifts the operating
staff has to check if the safety-related machine elements are in pro-
per service condition and complete.

K3 - 1
 3.0 Start - Up
Switching Machine ON

Attention! Main switch 78 /92

Prior to any commissioning and any change of shifts
the operating staff has to check if the safety-related
ON
machine elements are in proper service condition and 2
complete. OFF 1
3

1. If present: Unlock and remove the padlock at the main switch.

15
0
35
50 00
0

2. Turn main switch (1) from " 0 " to " I ". 1000

< Control voltage is switched on. After several seconds display shows 1500
3000

menu "Program-Data" >

2000
3. Push key Control Voltage On " I " (2)

< Main motor starts turning >

Main switch 115/137

Turning Machine OFF

15
0
35
50 00

ON 0

1. Wait until automatic operations have ended. 1000

2 OFF
1500
3000

1
2. Push key Control Voltage Off " 0 " (3)
Please note!
3

2000
Special equipment on machine types 78 and 92: By pressing the key the
blower motor is also shut off.
Main switch 155, 176
to prevent a start-up of the machine:

1. Turn main switch (1) from " I " to " 0 ".

2. Hook-in the padlock and lock it. ON

Please note: 2 OFF

1
You can mount up to three padlocks at the main switch (e. g. 1st padlock: .
operator, 2nd padlock: maintenance staff). 3

K3 - 2
3.0 Start - Up
Machine Identification

If the main drive unit of the machine is not yet ready after the machine has been Machine Identification (Electronical Type Plate)
switched on, an electronical type plate is displayed that lists the current machi-
ne data stored, as well as the data for the Polar safety checks (in Germany
according BGR 500*). Two weeks ahead of the inspection date, the machine –
after having been switched on - will indicate that an inspection is due. Once the
date of inspection has been reached, the note will be displayed every time the
machine is switched on.
When there are any requests or questions concerning the machine, indicate the
data on the type plate. In this way, the machine can be precisely identified.

Once the electronic type plate has gone out, the display shows the pop-up
window "What do you like to do?".
The operator can preselect a feature to get faster to the desired programming
mode:

1 Continue with old cut program

After this selection, the system indicates the most recently selected cutting
program.

2 Select new cut program

The system displays the program survey so that the user can select a free
or one of the existing cutting programs.

3 Create new cut program

Once this has been selected, another pop-up window is opened**.

The following selection can be made in the pop-up window:

1 Block Programming
The Block Programming mode is being started.

2 Program when cutting

The next available program data menu is displayed with the auxiliary
function "Program when cutting" activated. With every cut which is execut-
ed the actual position (= current position of the backgauge) is automatical- * regulations of the employers liability insurance association for safety and
ly saved in the program. health at work
3 Manual data input ** You can delete the window by pressing the "C" button / touch key. The
The next available program data menu to manually generate a program is machine is then started as usual and the program data menu is displayed after
displayed. that.

K3 - 3
 3.0 Start - Up
Machine Identification

Measurement Display and Measurement System Program Data Menu with pop-up window

Depending on what you have selected at "What do you like to do?", once you
have selected a program (Exception: preselection "Block Programming") the

Program Data Menu*

is being displayed.

It contains the measurement displayed on the top right corner of the display
showing the ACTUAL POSITION of the material gauge (backgauge position) of
the cutting machine. The actual position indicates the real backgauge position in
mm, cm, inches or sun = 1/10 shaku (Japan).
(To change over the measurement unit – please, refer to “Main Menu", page
K5B - 3)

Please note !
After the machine is switched on, and after every program change, an
information window in the program data menu is opened for approx. 3
seconds.

It shows the following information:

• Select level of pressure

Note for adjusting the desired clamping pressure / level of pressure. By
selecting a different size and/or clamp opening, the knife or machine can
be protected against damages by an excessive clamping pressure.

• Material correction selected

If a material correction and/or position correction had been adjusted prior
to the machine cutoff, the current correction data is displayed once the
machine has been switched on again.

* otherwise, see “Malfunctions/Breakdowns” (page K7 - 5).

K3 - 4
4.0 Manual Operation

K4 - 1
 4.0 Manual Operation 7 8 9
Setting of Measurements (Backgauge Movement) by Hand 4 5 6

1. Pull handwheel (3) or press keys simultaneously 1 2 3 D

< Backgauge advance, fast > C 0

7 8 9
4 5 6
1 2 3
2. Press center button of hand wheel or keys simultaneously C 0

< Backgauge reverse, fast >

3. Press key < Backgauge advance, slow >

4. Press key < Backgauge advance, slow >

Fine Adjustment by Hand

Push hand wheel back and turn right or left

< Backgauge can be moved to desired position >

K4 - 2
4.0 Manual Operation
Cutting Line Indicator, Mechanical with Clamp

Lower clamp with pedal onto stock:

a
The front edge (a) of the clamp is identical to the cutting line and can be used as
cutting line indicator.
Clamp can be stopped in any position.
Max pressure with fully activated pedal: 78 - 155: max. 30 daN
176: max. 50 daN

_________________________________________________________________

Cutting Line Indicator, Optical

ON

OFF

Actuate toggle switch (8) at main switch plate

15
Upper position: Table light ON

15
35

0
50 00
0
35
50 00

ON 0

middle position: "0" - position

100
0

1500
3000
8 OFF
100
0

1500
3000

lower position: Optical cutting line indicator ON

2000

2000
A thin light line indicates the cutting line;
the table light is switched off at that moment.

Clamping and Cutting

Starting the cut:

Push both cut buttons (4) simultaneously.

(Hold buttons until knife is on upstroke)! POLAR 92 X

Interrupting the cut:

Release one or both cut buttons: < clamp and knife stop immediately >

Continuing the cut:

4
Release and simultaneously push both cut buttons.

K4 - 3
 4.0 Manual Operation
Clamp Pressure Adjustment

Turn knob (5) to desired position 78 / 92 115 / 137

Stepless adjustment - ranges of adjustment: 78: 150 - 3000 daN
92: 150 - 3500 daN
115: 150 - 4500 daN
137: 150 - 5500 daN ON

(daN = kp) OFF

For type 155/176:

15

15
0

0
35
35
50 00

Adjustment of clamping force grade in menu "Machine Parameters" (see

0 50 00

ON 0

1000
1000

3000
OFF
3000

1500
1500

K5G-2)

2000

2000
Setting the Clamping Time Prior to Cutting
For bulky cutting material, it may be of advantage to set an extended clamping
time prior to cutting.
5
Adjustment of clamping time in menu "Machine Parameters" (see K5G-2)

Light Barrier
The lightbarrier (17) forms a curtain of invisible beams in front of the knife.
Any obstacle in the beams will stop clamping and cutting.
In that case the clamp can still be lowered with the pedal (indication of
cutting line).

Interference into the light curtain causes: POLAR 92 X

17 17
• clamping bar and knive to be stopped instantaneously
• a beep sound
• the monitor to display the message: CUT INTERRUPTED or
LIGHT BARRIER INTERRUPTED

To continue the cutting process:

Release cut buttons; trigger the cut again

K4 - 4
4.0 Manual Operation
Continuation: Light Barrier

The light barrier used is an infrared light barrier with twenty channels and a self- Display unit in the left-hand part of the light barrier (receiver side):
inspection system. This monitoring is indicated optically in the left-hand light
barrier (receiver side) by LEDs as part of a display unit.

The machine control system generates a test signal whenever ..

• a cut is released
• the lower dead centre of the knife is reached
• cutting is interrupted D2 D4

Meaning of LEDs in display unit

D6
D1 D2 D3 D4 D5 D6 Meaning
_________________________________________________________________ D5
on on on on off off Protect. area "unobstructed", light
reception excellent

off on on on off off Protect. area "unobstructed", light

reception good
D1 D3
off off on on off off Protect. area "unobstructed", light
reception just sufficient

on on off off on on Protect. area obstructed or a test is

performed

off off off off on on Protect. area has never been

unobstructed since Voltage ON

flashing off off on on Error

Attention!
In the case of a breakdown of the display unit the safety function of the
light barrier will not be impaired!

K4 - 5
 4.0 Manual Operation
Clamping with False Clamp Plate

The clamp plate avoids clamping marks on sensitive stock.

Attaching false clamp plate:

6.2
Push plate against clamp from underneath until you hear guide
pins (6.1)snap.

Removing of false clamp plate:

1. Lower clamp with pedal approx. 2" above table.

2. Use tipped ends of both knife handles (in tool box) to push locking pins
(6.2) back simultaneously.
Plate drops!

* Also refer to "Press Material" (Fix clamp), page K5B - 38

Important notes for the use of false clamp plates

When using false clamp plates of different widths for the pressure clamp, please
observe that the clamping pressure must always be adjusted to the conditions
mentioned below, in order to prevent any negative effects to the cutting quality. 6.1

The clamping pressure depends on

- the type of material being cut, Flexible False Clamp Plate (Optional Equipment)
- the width of the material,
- the feed depth of the material, Flexible false clamp plate compensates uneven stock and supplies even pres-
and sure across the whole pile.
- the width of the false clamp plate being used. (Mounting/removing - see regular false clamp plate)

Consequently, the pressure must be determined in practice.

Caution! Please note!

An excessive clamping pressure with regard to the above mentioned
conditions may result in considerable damages to the knife, especially
when dealing with carbide-tipped knives. In extreme cases, there is a risk
that the clamp and the knife will collide. Parts chipping off the knife may
severely injure the operating staff!

K4 - 6
4.0 Manual Operation
Air Table

The table surface of the machine is equiped with air jets. After turning on the air 16
supply, the stock can be moved easily.

Switching air supply on:

Basic adjustment:

• Press key (16) once = air supply On/Off to front table only
• Press key (16) twice = air supply On/Off to complete table

An activated air supply is shown by a pictograph in the measurement section of

the display.

Note!
On XT models, the air table switch in the "Preset functions" menu, - selection
"Preset program functions", - selection "Configure air table switch" (see page
K5B - 34) can be configured in two variants.

Attention!
When automatic backgauge is switched on air supply is automatically
turned on for every backgauge return movement. Automatic air supply can
be added to the programming of any backgauge position stored.

Switching air supply off: automatically upon every cut

or
by pressing any of both cut buttons
or (if pre-selected)
actuate foot pedal (see page K5B - 34)

K4 - 7
K4 - 8
5.0 Automatic Operation

K5A-1
 Introduction
All of the XT models are equipped with touch screen terminals. The menu Program Data menu and Program Information menu are meant for the
selection is made by touching the superimposed menu symbols (touch input of order data and cut sizes or the display of additional information
keys) with your finger on the display. Position input, manual backgauge concerning a particular program. Operator prompting is available on all
movement, distortion and cut correction as well as special functions are display levels using key symbols, function pictographs and indications.
still input in the usual way via the control console.
In the Program Directory the user can view all the allocated programs
in the memory. You can select, delete, copy programs or provide them
On X models, the operation is generally carried out via the keys on the with a protection. The programs can be stored in two memory segments
control console. (A and B). Each memory segment has a capacity of 999 programs.

A position (cut size) input via numerical keypad can be permanently stored.
The Main Menu offers the possibility to select various program and
The complete data (cut sizes, information, additional functions) of a job can machine functions.
be stored under a program number. It is possible to enter and store as
many cut sizes in each program which are necessary for processing the
pile of material. Via menu keys you can store additional functions for the individual cut
Additional information can be stored together with the cut size. This makes sizes. These functions will accompany and/or facilitate and speed up the
the sequence of operation more clearly and allows information about a work cycle.
program to be obtained at a glance.
You can also store cut sizes automatically when a cut is released.
On the numerical keypad you can carry out calculating operations in the
The transfer of data to external storage makes the storage capacity four fundamental operations of arithmetic. A "Memory Function" is
virtually unlimited. available.

A programmable automatic backgauge function as well as an automatic If the machine is equipped with a special backgauge (e. g. swivel / tilting
knife function enable the cutting material to be automatically advanced of / Fixomat backgauge) the control console has an additional control panel
to the next position stored once it has been cut, or the cut to be triggered for activating the corresponding backgauge functions.
automatically after the cutting position has been reached.

POLAR-Eltrotact provides the machine with a repeater device in order to If the machine is equipped with optional machine equipment the main
process constant cutting sequences in a fast and simple way control console is complemented by additional control panels accommo-
dated in the front panel and/or in one or even both of the light-barrier
housings. These are first of all meant for performing manual functions,
The data and information is shown on the display in four basic menus:
such as retractable side gauges, stationary stack lifts, Autotrim functions
1. Program Data and automated functions for the Transomat loading units.
2. Program Information
3. Main Menu
4. Program Directory

K5A - 2
Introduction
Functions of the menu keys*
78X/XT 92X/XT 115X/XT 137X/XT 155X/XT 176X/XT 78X/XT 92X/XT 115X/XT 137X/XT 155X/XT 176X/XT

Basic display "Main Menu"

Menu key "Machine Parameters"
(Program-/Step Parameters)
Language x x x x x x
Measuring unit x x x x x x Pressing time before cut x x x x x x
Copy program x x x x x x Pressing time no cut x x x x x x
Block programming x x x x x x Pressing force level - •² •² •² x x
Production report x x x x x x Pressure force sensors - - •² •² •² •²
Sheet size tables x x x x x x Clamping force table • •² •² •² •² x
Service x x x x x x Backgauge acceleration x² x² x² x² x² x²
Knife change / compensation x x x x x x Backgauge deceleration x² x² x² x² x² x²
Maintenance cut counter x x x x x x Backgauge speed x² x² x² x² x² x²
Preset cut counter x² x² x² x² x² x² Backgauge smooth stop x² x² x² x² x² x²
Preset functions: x x x x x x Optimization of clamp x x x x x x
Machine setup x x x x x x Clamp Light barrier - - •² •² •² •²
Setup program functions x x x x x x Smooth prepressure - - •² •² •² •²
Setup serial interface x x x x x x Highspeed cutting - - •² •² •² •²
Setup production report x x x x x x Autotrim blowing air - - •² •² •² •²
Press material x x x x x x Start/Stop Autotrim air - - •² •² •² •²
Correction for material x² x² x² x² x² x² Time to align or remove - x² x² x² x² x²
Clamp unit at knife - - •² •² •² •²
Clamp up when knife = BDC x² x² x² x² x² x²
Menu key "Optional functions"

Automatic knife ACTIV x x x x x x

Automatic knife PREPARED x x x x x x
Clamping without cut x x x x x x Menu key
Jogging mark x x x x x x "Auxiliary functions"
Air supply front table ON - - • • x x
Air supply complete table ON x x x x x x
Programming with cut x x x x x x
Air supply complete table OFF x x x x x x
Calculating a size x² x² x² x² x² x²
Step parameters x² x² x² x² x² x²
Set/Delete program protection x x x x x x
Autotrim waste - - •² •² •² •²
Simulation of cutting sequence** x² x² x² x² x² x²
Autotrim align material - - •² •² •² •²
Correction of nominal position** x x x x x x
AT label pusher - - •² •² •² •²
Warning: skip cutting** x x x x x x
Lay guide I x² x² x² x² x² x²
CountMonitor (Progress control) x x x x x x
Lay guide II x² x² x² x² x² x²
Correction of position x² x² x² x² x² x²
Align material x² x² x² x² x² x²
PL-block branch table** x² x² x² x² x² x²
EasyMode x² x² x² x² x² x²
CountMonitor • • • • • •
Clamp unit at knife - •² •² •² •² •²
Backgauge advance, slow x² x² x² x² x² x²
Automatic Ejector OFF x² x² x² x² x² x²
Swivel backgauge - - •² •² •² •² Menu key
Tilting Backgauge - - •² •² •² •² "External add. functions"
Fixomat - - •² •² •² •²
Retractable side gauge - - •² •² •² •² 4 pos. freely assignable upon backgauge start x² x² x² x² x² x²
Holding down clamp at backgauge - - •² •² •² •² 4 pos. freely assignable upon backgauge stop x² x² x² x² x² x²

Menu key "Program functions"

Menu key
"User defined additional functions"
Nominal position x x x x x x
Progr. Ejector x x x x x x
Eltrotact x x x x x x 27 freely assignable positions for user defined
ET Block with absolute pos. x x x x x x additional functions x² x² x² x² x² x²
Program loop x x x x x x
Comments x x x x x x
Program parameters x² x² x² x² x² x² Alphabetic keypad: "Enter" touch key x² x² x² x² x² x²
Alphabetic keypad: "Enter" soft key x³ x³ x³ x³ x³ x³

- function not available x³ only on X-machines

x function available • optional equipment * Technical alterations reserved
x² only on XT-machines •² optional equipment, only on XT-machines ** with automatic mode only

K5A-3
 5.0 Automatic Operation
Basic Menu: Program-Data

Press key / touch key "Program-Data "Program Data" menu in status "Input Mode ON":
< display shows Program-Data menu:(appears automatically after start-
up*) >
1 4
Sections of the "Program Data" menu (here: XT model)
8 9

1 Program Header (order section with order data, program information,

10
started production report (T1..)) 2
11
2 Program Data section (cut sizes / comments / program functions)
6
3 Input section (nominal size, calculating operations, comments)

4 Cut size section and indication of current machine functions in the 3 5

form of pictographs (e. g. clamping stage, air supply for entire table,
program / step / machine parameters etc.)

5 Operator prompting (pictographs)

6 Function indicator of optional equipments (superimposed alphabetic 7

keypad, numerical keypad and options windows, such as swivel
backgauge, tilting backgauge, etc.) "Program Data" menu in status "Input Mode OFF":

7 Status indicator (current machine functions, alert functions)

8 "Step indication" cursor

9 Correction section (extension of the cut size section)

10 Display section "additional functions" (pictographs)

11 Scroll bar / cursor keys

* If this fails, see "Malfunctions/Breakdowns", page K7 - 1.

K5A - 4
5.0 Automatic Operation
Continuing Basic Menu: Program-Data

To 1 Program heading shows: To 5 The "Operator prompting" area indicates:

Pictographs for operator guiding (key input)
ORDER order no/name (is only displayed after it
has been entered in the "Program Informa-
tion" menu) To 6 On the display panel "Additional functions / Optional
special equipment" the following data is displayed:
PROGRAM-NO number of selected program and memory
bank e.g. 1 A = program 1, memory bank A Insertion of an additional function stored (e.g. retractable side
gauge, swivel backgauge etc.) of the machine as well as its
STEP total number of steps used in that program functional positions and adjusting values.

Running production report (T1)

To 7 Status display

To 2 Data section shows: Indication of actual machine function as well as warning messages

consecutive number of each step in the program

To 8 Cursor "Step"
stored size (cut measurement) or comment
Indication of current program step
(Pictographs) Additional Functions: indication of picto-
graphs of stored additional functions
To 9 Correction panel (Expansion of cut size display)

To 3 Input section shows: Distortion value, cut correction value, nominal position correction
and lay guide adjusting value
Inserted sizes, comments, program hints
DISTORTION - distortion value adjusted
LABEL CORR. - cut correction value adjusted
To 4 Size display shows: LAY GUIDE - lay guide correction value adjusted
NOM. POS. - nominal position adjusted (in automatic mode)
ACTUAL POSITION actual backgauge position/ measurement
system
To 10 Display panel "Additional functions"
NOMINAL POSITION display of next backgauge stop
Indication of programmed additional function(s) of a particular record
actual active machine function (pictogrphs) as a pictograph

K5A-5
 5.0 Automatic Operation
Basic Menu: Program Information

Press key / touch key X model D

i Alphabetic keypad minimized

The "Program Information” menu provides the possibility to store additional data
related to the specific order in the program stored in the Program Data menu.
The information can be input either via the numerical keypad and/or as a plain
text on the superimposed alphabetic keypad.

Plain-text input on the X model

On the 78 X - 176 X models alphabetic text can be input with a soft-key function XT model
only. This means, a keypad is superimposed on the display and you have to
select the individual characters using the cursor keys.

Plain-text input on the XT model

On machine type XT, a touch-sensitive alpha keypad is superimposed.

For the "storage of information" - refer to page K5A - 26

If the "Production Report” function has been activated (see page K5B - 24) every
selection of the Program Information Menu is followed by the display of a pop-up
window that indicates the user’s defined personal data.
The pop-up window is hidden by

on X model: pressing key

on XT model: by touching the section Alphabetic keypad maximized

Other input or machine-modes, resp. in this display:

• Program Selection
• Set/Delete Program Protection (with menu key "Auxiliary Functions", page
K5F - 2)

K5A - 6
5.0 Automatic Operation
Basic Menu: Program Directory

Press key / touch key

X model
D E
The Program Directory shows all stored programs of the selected memory with the
following data: i

a. (display top): - A - = memory A

b. P. NO = program number; graphic programs are shown in

"red" (usually: white)

c. SN = number of steps (cut sizes / comments) used in

that program; graphics programs are displayed in
"blue” (usually in black).

d. ORDER = order number or name; graphics programs are

displayed in "blue” (usually in black).

e. 1/1 = indication of selected page

Please note:
On one "page", up to 10 programs can be displayed.
If more programs have been assigned,
on X models: - use the cursor keys (quick page selection by preselecting XT model
the "page selection" key (E)
on XT models: - use the "scroll bar" (A) touch key, the "page" touch keys (B) or
the "cursor" touch keys (C)

to scroll to the following pages. D

The selection of memory A/B is made B
on X models: via the "Program Selection" menu
on XT models: via touch keys "Memory Selection" (D).
Each of the memory segments (A / B) has a capacity of 999 programs. A

This basic mask offers the following functions:

• Program selection (see page K5A - 12/13) C
• Deleting program(s) (see page K5A - 30)
• Deletion of complete memory (see page K5A - 30/31)
• Set / Reset program protection (see page K5A - 34/35)
• Copy programs (see page K5A - 32/33)

K5A-7
 5.0 Automatic Operation
Basic Display: Main Menu (Function Survey)

Press key / touch key X model

D

i
The Main Menu shows all available computer operations.
Here the operator finds all the help to set up, modify and delete programs.
He can also select and activate several other devices.

The changeover (active side / passive side) between "Program Functions" and
"Machine Functions" and vice versa, is made on
XT model
• the X model: via cursor keys right / left or the "0" key on the numerical keypad
or
• the XT model: by touching the function side or the "cursor" touch keys (A)

Select and run any of the operation see page K5B - 2

function side, active

K5A - 8
5.0 Automatic Operation
Cursor Movement in Basic Menu (types 78X - 176X)
D
The XT models, owing to their touch functionality, are provided with Cursor keys
touch-sensitive cursor keys and/ or a scroll bar on the display. i
Cursor = indicator

The basic menus contain two kinds of cursor :

7 8 9
A. Cursor "step" (>, in program-data-section)
4 5 6
B. Cursor "input" (-, flashes in input-section)
1 2 3
C 0
Cursor movement:

Meaning:

Cursor "step":
Cursor "Step"
Cursor "input":

Operation

pressing of keys or once

< cursor moves to next step (up or down) or input digit >

pressing of keys constantly:

< cursor moves constantly up/down >

only cursor "step":

if together with key or key is pressed

< cursor will "jump" to first or last step in Program Data section or Program
Directory > Cursor "Input"

K5A-9
 5.0 Automatic Operation
Automatic Backgauge Adjustment through Numerical Keypad

Input under provision that monitor shows program-data-display.

The backgauge can be positioned at a particular size by entering a value via
numerical keypad and subsequently triggering the positioning by means of the
equality key.

A Measurement input with metric system (cm)*

Measurement/positioning Key input

A
1. 30,735

2. Positioning X model: press 2x briefly

XT model:
as on X, or press the "Trigger function"
touch key (A) ("Input Mode Off" !)
_________________________________________________________________

B Measurement input in inches*

Same way of input as for metric system after 1. input

however "Input section"
value in inches entered as a fraction:
after 2. input
Measurement/positioning Key input "Operation display" (backgauge moves)

after backgauge stops

1. 12 1/2" "Measurement display"

2. Positioning X model: press 2x briefly

XT model: as on X, or press the "Trigger function"
touch key (A) ("Input Mode Off" !) after 1. input : 12.500

Note: after 2. input: AUTOMATIC POSITIONING ACTIV

For whole sizes (no digits behind decimal point) zeroes do not have to be
keyed in. This is done automatically. after backgauge stops: ACTL. POS 12.500 inches
NOM. POS 12.500 inches

K5A - 10
5.0 Automatic Operation
Deletion of a Wrong Input in Input Section D

i
X model: XT model:
Press < nom.pos in input section is deleted >

-----------------------------------------------------------------------------------------------------------
7 8 9
Input Error: Value of Nom. Backgauge Position too 4 5 6
Low/High
1 2 3

If a nominal size is inserted which cannot be reached by the backgauge the C 0

following reaction will be caused:

< a beep will sound - operation display: BACKGAUGE LIMIT >

Remedy: Press , Insert correct size

D
Moving Backgauge to a Nominal Position (Positioning)
i
1. Enter size with numerical keypad X model: XT model:

2. X model: press twice shortly

XT model: as on X, or press the "Trigger function" touch key (A)
("Input Mode Off" !)
7 8 9
< Backgauge moves to nom. pos. forward or backward > 4 5 6
1 2 3
Deletion of a wrong input A
C 0
Press key

K5A-11
 5.0 Automatic Operation
Selection of a Free Program

This selection is possible in following basic menus: Program Data X model D

Program Information

Procedure:
Program Directory
i
X model: Press the "Program selection" key

or

Select the "Program Directory" key

XT model
XT model: Press the touch keys "Input ON" + "Program Selection"
or
Press the "Program Directory" touch key
Menu
< The selection menu is displayed> "Programm
Selection"
Display: The currently selected memory is displayed vertically in the for
ground and highlighted in a different color. The storage capacity is selected
displayed as a percentage (%). memory

In the "Program Selection" menu:

Menu item
"Vacant program" The next vacant program of the currently selected
memory segment is shown in green.

Menu "Program Directory":

Input section: displays the next vacant program of the currently

selected memory segment.

Selection: Menu
"Programm-
X model: Select menu item "Vacant program" Directory"
XT model: Press the "Trigger function" touch key in the input section

< A vacant "Program Data" menu is indicated >

K5A - 12
5.0 Automatic Operation
Selecting a Program

Possible in following basic menus: Program Data X-model D

Program Information
Program Directory
i
Two calling modes:

A. According to program number

B. Search for order name / order number

XT-model
A. According to program number:
Menu
1. X model: press key "Program Selection" "Programm
or Selection"

press key "Program Directory"

XT model: press touch keys "Input Mode On" + "Program Selection"

A
or
press touch key "Program Directory"

< selection menu is displayed;

2. X model: Select "Memory Seg. A/B"

XT model: press the touch key "Memory Selection" (A)
< program directory of the selected memory segment A or B is displayed >

3. Select / enter the desired program number

4. Press key resp. press touch key "Trigger Function" Menu
"Programm-
Directory"
< Program Data menu of desired program appears >

K5A-13
 5.0 Automatic Operation
Conti.: Selecting a Program

B. Search for order name / order number: X model

Note: Previous storing of order names/numbers to all programs is D

conditional (see storing of program information, page K5A - 26))
i
1. X model: press key "Program Selection"
XT model: press touch keys "Input Mode On" + "Program Selection"

2. Select "Search Order"

< Selection menu is displayed; Alphabetic keypad is superimposed (on XT

model in minimized form).
On XT model: Maximize the alphabetic keypad! >
XT model
3. Enter order name/order number via alpha or numerical keypad *

< Order name/ order number is displayed on input panel >

4. X model: press key "Enter"

XT model: as on X, or press the "Trigger Function" touch key

< the desired program (order) is displayed in Program Data menu >

* Note:
Input of order name/number can be done by entering only a part of the name or
the number.
After pressing the "equal" key the computer will "search" for the desired order
according to the entered letters resp. numbers. In case memory contains several
orders with the same letters/numbers display will show the next program number
whose order name/number matches the entered letters or numbers.

K5A - 14
5.0 Automatic Operation
Storage of Measurements

Only in Program-Data menu!

1. Select free program (page K5A - 12)

2. Enter the nominal size via the numerical keypad

(On XT models, the numerical keypad can be superimposed/hidden on the

display by touching
- the touch key "Superimpose numerical keypad ON/OFF" (A)
or
- touching the input section (D)

(e.g. size 23,5 cm); key input:

A
3. X model: Press "Enter"
XT model: as on X, or press "Trigger function" (B) or "Enter" on the
superimposed numerical keypad (C)

< beep sounds; nom. pos. is on step 1 in Program Data section >

Note: D B C
Display can show up to 9 steps (lines). When entering step 10 former step 1 will
disappear into screen memory.

K5A-15
 5.0 Automatic Operation
Setting Up a Cutting Program, Example 1

Two side trim on size DIN A3 X model XT model

untrimmed size 31 x 43 cm
D
1. Cut size: 30,5 cm
2. Cut size: 42,5 cm i

Key input:
A
(On XT models, the numerical keypad can be superimposed/hidden on the
display by touching 7 8 9
- the touch key "Superimpose numerical keypad ON/OFF" (A)
4 5 6
or
- touching the input section (D) 1 2 3
C 0
1. Call up a free program

2.

3.

4. Set cursor to first step number

Running the program: Cut sequence: 2

X model: 1. Press the key "Automatic ON"

2. Press the key 2x

XT model: 1. Press the touch keys "Input Mode OFF" + "Automatic ON"

2. as on X, or press the "Trigger function" touch key (A)

1
< Backgauge moves to first cutting position; after the cut is triggered:
ejector moves forward; after that the second cutting position is approached >

K5A - 16
5.0 Automatic Operation
Setting Up a Cutting Program, Example 2

Round trim with following cuts; Cut sequence:

Starting size DIN A3 untrimmed 31 x 43 cm;
Finish size DIN A4 (21 x 29,7 cm)

Cut sizes:
4 5 2
1. 30,5 cm
2. 42,5 cm
3. 29,7 cm 3
4 42,0 cm
5. 21,0 cm
.
Key input:

(On XT models, the numerical keypad can be superimposed/hidden on the

display by touching 1
- the touch key "Superimpose numerical keypad ON/OFF"
or
- touching the input section

1. Call up a free program

2.

3.

4.

5.

6.

K5A-17
 5.0 Automatic Operation
Step Selection

X model: press key "Step Selection" X model

XT model: press touch keys "Input Mode On" + "Step Selection" D

Select Step Number i

1. Make selection "Select Step Number"

2. Enter desired step number via numerical keypad

3. X model: press key

XT model: as on X, or press the "Trigger function" touch key

< cursor marks step number in Program Data menu > XT model

Erase Step(s) With Number(s)

1. Make selection "Erase Step(s) With Number(s)"

2. Enter desired step number o r

enter various step numbers, such as e.g.

3. X model: press key "Enter"

XT model: as on X, or press the "Trigger function" touch key

< step number/s is/are deleted >

K5A - 18
5.0 Automatic Operation
Continuation: Step Selection

Correct / Include Additional Functions (to several

step numbers)
1. Make selection "Correct / Include additional functions"

2. Select desired step numbers (under which this function is to be stored,e.g.

3 - 5)

3. Press key < "Additional Functions" window is displayed >

4. Select desired additional function(s)

< Additional function(s) appears in input section >

5. X model: press key "Enter"

XT model: as on X, or press the "Trigger function" touch key

< Program data menu is shown; pictograph of stored additional function

is displayed behind the cut size >

Erase Additional Functions (of several step numbers)

1. Make selection "Erase Additional Functions"

2. Enter step numbers (e.g. 5 - 8)

3. Press key < "Additional Functions" window is displayed >

4. Select additional functions to be erased

< pictogaphs of the additional functions appears in input section >

5. X model: press key "Enter"

XT model: as on X, or press the "Trigger function" touch key

< Program Data menu appears; additional function pictographs behind

the cut sizes are deleted >

K5A - 19
 5.0 Automatic Operation
Continuation: Step Selection

Transform ET-Block Using Absolute Positions

This function serves to convert programs generated in Eltrotact mode into

absolute positions. When a program is converted into absolute positions, the
single cut sizes can be corrected much easier. The cut sizes are also available
for a distortion correction that might become necessary.

Procedure
1. Select "Transform ET block using absolute positions"

2. Enter step numbers of Eltrotact block from first label size up to total cuts

3. X model: press key "Enter"

XT model: as on X, or press the "Trigger function" touch key

< Eltrotact block will be transformed to absolute positions >

Copy Program Steps into Clipboard (Program Section)

The menu serves for copying program sections or an entire program. In this way,
program sections (steps) can be easily inserted into or attached to other pro-
grams.

Procedure
1. Select "Copy program steps into clipboard"

2. Enter step numbers (e. g. 5 - 9) to be copied

3. X model: press key "Enter"

XT model: as on X, or press the "Trigger function" touch key

<Step numbers are stored in the intermediate deposit. When the intermedi-
ate deposit contains data, this is indicated by displaying in blue the menu
item "Insert/Add from intermediate deposit" . The data stored in the inter-
mediate deposit can be simply overwritten. The intermediate deposit is only
cleared when the machine is shut off.

K5A - 20
5.0 Automatic Operation

Continuation: Step Selection

Insert/Append from Clipboard

Program steps can be inserted from the clipboard into the presently selected
program, or any program you wish. When the intermediate deposit contains data,
this is indicated by displaying the menu item "Insert/Add from intermediate
deposit" in blue.

Procedure

if the data stored in the intermediate deposit is to be inserted into the current
program:

1. Select function "Insert/append from clipboard"

2. Select the step number from which the data is to be inserted

3. X model: press key "Enter"

XT model: as on X, or press the "Trigger function" touch key

< step numbers from the intermediate deposit are inserted into the program >

or

if the data stored in the intermediate deposit is to be inserted into a selected

program:

1. Call the requested program (program selection)

2. Select function "Insert/Add from intermediate deposit"

3. Select the step number from which the data is to be inserted

4. X model: press key "Enter"

XT model: as on X, or press the "Trigger function" touch key

< step numbers from the intermediate deposit are inserted into the program >

K5A - 21
 5.0 Automatic Operation
Correction of an Input

A. Correcting before storing X model

(nom.pos./comment is still shown in input section)

1. Press key < Nom. pos./comment in input section disappears >

2. Enter correct size/comment

B. Correcting after storing

(Nom. pos./comment is shown in Program Data section)

1. Select step number

2. X model: press key "Correction"

XT model
XT model: press touch keys "Input Mode On" + "Correction"

3. Enter right size/comment

4. X model: press key "Enter"

XT model: as on X, or press the "Trigger function" touch key

K5A - 22
5.0 Automatic Operation
Automatic ON/OFF (Automatic Forward)

X model: Keys "Automatic On" and "Automatic Off" X model

XT model: touch keys "Input Mode On" + Automatic On" / "Automatic Off"

Automatic ON:

Press key/touch key "Automatic On"

An automatic backgauge advance to next cut size can be released by:

• actuating the hand wheel or
• actuating of one of the backgauge movement keys or
• pressing equal key twice or
• cutting
XT model
< Operation display reads: AUTOMATIC
Input section shows step marked by input cursor >

Automatic OFF: Press key/touch key

< automatic backgauge movement is stopped immediately >

Attention!
When automatic is switched on the following operations are not possible:

• programming
• automatic setting of backgauge through size input
(the "handwheel function" for size correction remains reliable)

Positioning check in automatic operation

For example, when a positioning process in automatic operation has been inter-
rupted (cutting position has not been reached!) and the operator tries to release a
cut in automatic mode after that, a visual and audible indication is made
"GO TO POSITION"

When the position must be moved to:

X model: press key twice or press one of backgauge movement keys
XT model: as on X, or press the "Trigger function" touch key

K5A - 23
 5.0 Automatic Operation
Automatic Knife OFF

Application: X model

Switch off an activated automatic knife function previously programmed.

Switch off automatic knife:

manually: X model: press key

XT model: press touch key "Automatic Off"
.
automatically upon: - backgauge return
- step change via cursor XT model
- change from "Lay guide I" to "Lay guide II" or vice
versa
- finished "Program Loop" function

Manual start-up of an activated automatic knife function can no longer be

performend!

(see also "Additional function: Automatic Knife Prepared/Active", page

K5C-4)

An automatic knife function can only be activated within the program using the
additional functions "Automatic Knife Prepared" or "Automatic Knife Active".
If none of the two additional functions has been programmed together with the
nominal size, the automatic knife will be switched off.

K5A - 24
5.0 Automatic Operation
Running a Cutting Program

Example: Setting a cutting program, example 1, see page K5A-16 X model

1. Call program < display shows program data >

2. Switch on Automatic operation:

X model: press key "Automatic On"

XT model: press touch keys "Input Mode Off" + "Automatic On"

< Operation mode: AUTOMATIC, Input section: 30.500

XT model
3. X model: press key 2x shortly or pull handwheel or press
reverse button in handwheel*.

XT model: as on X, or press the "Trigger function" touch key

< Backgauge moves to 1. cut size >

4. Align stock

5. Make cut

After cut:

- backgauge advances approx. 23 cm (automatic ejector function)

- then reverse to 42.5 (with automatically activated air table)

6. Turn stock by 90° and line up

7. Make cut
After last cut of a program:
- Cursor jumps back to 1. step
- Backgauge moves automatically to that size

* no ejector during this operation

K5A - 25
 5.0 Automatic Operation
Storage of Program Informations

Press key/touch key "Program information" X model

Possible input variants: D

A Input via numerical keypad
i
B Input of plain-text information via the touch key alphabetic keypad
(XT models)
C Input of plain-text information via the soft keys (X models)

In the factory, nine positions have been preset in the left-hand half of the display.
These positions can be provided with the respective pieces of information. Six
positions are especially designated for a job-oriented progress report which
provides an automatic recording of quantities via function "Get new material"
from the menu "Program Functions" – Selection "Comments" – Selection "Func- XT model
tional comments". The parameters can also be entered manually.
In the right-hand half of the display, in the "Comment" section, the user can enter
any remarks or data he/she wishes to (e.g. storage locations etc.).
Maximum input capacity: 8 lines!

On machine types 78 X – 176 X the alpha input is performed via softkey input.

Input via softkey:

1. Press key (multiply) <keyboard is displayed>

2. Select a character using the cursor (with the “equals” key you can jump
over five characters in a line)

3. Press “Cursor-Home” key < character is inserted into input section >

Delete an input:
1. Press key (multiply)
2. Press key

The storage process can be corrected by pressing the key "Correction".

K5A - 26
5.0 Automatic Operation
Storage of Program Informations

To maximize the alphabetic keypad:

X model: Press the "Multiplication" key
XT model: Touch the minimized keypad

Positioning of the alphabetic keypad

On the XT models, you can position the alphabetic keypad on the display at your
own discretion.

To do this ...
1 Touch the red pin (A) above the keyboard <arrow symbol is shown>
2. Touch any desired area on the display
< The keypad will be positioned at this place>

Storage procedure (example: "Order"):

1. Enter the order number or name of order A

< Order number / name is indicated in the input section of the alphabetic
keypad and in the input section of the display >

2. X model: Press key "Enter"

XT model: Actuate the "Enter" key on the alphabetic keypad
or the touch key "Trigger function"

< You can hear a whistle sound; the order number / name is stored at
"ORDER" >

3. Select the next line, etc.

Exit the program information image:

Select menu "Program-Data"

< Program Data menu is indicated; if order number / name has been stored as
part of the program information, it is to be found in the heading (order section)
under the title “ORDER” >.
"Trigger function" Enter

K5A - 27
 5.0 Automatic Operation
Deletion of a Step Number (Measurement / Comment)

See also "Step Selection", page K5A-18 X model XT model

1. Select program < Program Data Display appears >

2. Select step (with cursor or step selection)

3. X model: press key "Delete"

XT model: press touch keys "Input Mode On" + "Delete"

< operation mode: DELETE >

4. X model: press key "Enter"

XT model: as on X, or press the "Trigger function" touch key

< size resp. comment (step) is deleted. Note: all following steps move down
by one number >

Deletion of Several Step Numbers (Program Section)

1. Select program < Program Data Display appears >

2. X model: press key/touch key "Step Selection"

XT model: press touch keys "Input Mode On" + "Step Selection"

< menu appears >

3. Select "Erase Step(s) With Number(s)"

4. Enter step no. to be deleted (e.g. 5 - 7)

5. X model: press key "Enter"

XT model: as on X, or press the "Trigger function" touch key

< step 5 to 7 are deleted >

K5A - 28
5.0 Automatic Operation
Deleting a Program / Several Programs

Possible variations: X model

A. Deleting in Program Data Display or Program Information D

Display
i
B. Deleting in Program Directory Display

A. Deleting in Program Data Display or Program Information

Display

Note! XT model
In the Program Data/Program Information Display only the current shown
program can be deleted.

1. X model: press key "Program Selection"

XT model: press touch keys "Input Mode On" + "Program Selection"

< menu appears >

2. Select "Delete Current Program"

3. Program number to be deleted appears in input section

4. X model: press key "Enter"

XT model: as on X, or press the "Trigger function" touch key

< current program is deleted >

K5A - 29
 5.0 Automatic Operation
Continuation: Deleting a Program / Several Programs

B. Deleting in "Program Directory" menu: D

Please note! i
In the "Program Directory" menu you can delete one or more programs.

X model:
1. Select the "Program Directory" key
Menu
2. Press the "Program selection" key and select "Memory segment "Program Selec-
A/B" < Program directory of the selected memory segment is displayed > tion"

3. Press the "Program selection" key once more

4. Select "Mark programs" < Program directory is displayed >
selected
5. Enter the program number(s) via numerical keyboard and confirm each memory
one with " " * (e.g.: 1 ,3 , etc.)
6. After all the program numbers have been input: Press the "Enter" key

< the programs to be deleted have been highlighted. "Program selection"

menu is displayed:

7. In order to delete the previously marked programs:

select "Delete program(s)"
To cancel all the marks:
Select "Delete all marks"
< in the input section: The number of the programs to be deleted is dis-
played and all the marks are deleted >

8. To activate the deleting process: Press the "Enter" key** Menu

"Program
Directory"
*Please note! When the program numbers 1 - 999 are input the complete mem-
ory will be cleared!

** The deleting process can be aborted by pressing the key before the

"Enter" key is pressed.

K5A - 30
5.0 Automatic Operation
Continuation: Deleting a Program / Several Programs

Please note! Program Directory, XT model

It is possible to enter a maximum of 7 unarranged program numbers (such as
e.g., 2. 5. 7. 9. 11. 13. 18.)! selected memory with "Memory selection" touch key
The individual program numbers must be separated by decimal points.

XT model:
1. Press the "Program Directory" touch key

2. Select Memory segment A or B with touch key "Memory selection"

3. Press the touch keys "Input ON" + "Marking" (A)
B

4. Select (mark) the program number(s) to be deleted or input via num.

keypad*. Use the "page" touch keys (B) to scroll through the menu.

5. Press key "Enter" or "Trigger function" key**

< All the sizes and pieces of information of the programs are deleted. Protected
programs remain stored in the memory. They can only be deleted, after their
program protection has been canceled (see page K5A-34/35) >

*Please note! When the program numbers 1 - 999 are input the complete mem-
ory will be cleared!

** The deleting process can be aborted by pressing the key before the

"Enter" key is pressed.

K5A - 31
 5.0 Automatic Operation
Program Directory: Copy Programs

X model:
D

1. Select the "Program Directory" key i

2. Press the "Program Selection" key
3. Select "Memory Seg. A/B"
< Program directory of the selected memory segment is displayed >

4. Press the "Program selection" key once more

5. Select "Mark programs"

< Program directory is displayed > Programm Directory / Program Selection

6. Enter the program number(s) to be copied via numerical keyboard and

confirm each one with " " (e.g.: 1 ,3 , etc.)

7. After all the program numbers have been input: Press the "Enter" key
< the programs to be copied have been highlighted. "Program selection"
menu is displayed >

8. Select "Copy program/s"

< "Destination memory" image is displayed >

9. Select destination memory via keyboard (memory A = 1; memory

B = 2)
< Program directory is displayed showing the destination program from
which the programs to be copied are to be inserted>

10. Press the "Enter" key

<in input section. "Copy complete" window is displayed, indicating the
number of copied programs >

Copy complete: Press key

K5A - 32
5.0 Automatic Operation
Continuation Program Directory: Copy Programs

XT model:

1. Press the touch keys "Input Mode On " + "Mark" (A)

2. Select Memory segment A or B with the "Memory selection" touch key A

3. Select (mark) the programs you want to copy or input them via numerical
keypad (e. g.: 1 ,3 , etc.)*

4. Press the "Copy" (B) touch key

< "Memory selection" is displayed >

5. Select destination memory A or B

< The input section shows the program directory with the destination
program from which the programs to be copied are to be inserted >

6. Accept destination program by pressing the "Enter" key or the "Trigger

function" touch key, or enter a different destination program via numeri-
cal keypad. B

< Input section displays the program directory of the selected memory segment
with a status message of the copy procedure and the number of programs
already copied >

*Please note!
When the program numbers 1 - 999 are input the complete memory will be
copied!

K5A - 33
 5.0 Automatic Operation
Program Directory: Set / Reset Program Protection

Set program protection on (X model) D

i
1. Select the "Program Directory" key

2. Press the "Program selection" key

3. Select desired memory segment via "Memory Seg. A/B" selection
< Program directory of the selected memory segment is displayed >

4. Press the "Program Selection" key once more

5. Select "Mark Programs"
< Program directory is displayed >

6. Input the program number(s) to be marked via the numerical keypad and
confirm each input by " " (e. g.: 1 ,3 , etc.)

7. After all the program numbers have been input: Press the "Enter" key
< the programs to be protected have been highlighted. The "Program selec-
tion" menu is displayed >

8. Make selection "Set Program Protec."

< Program directory is displayed. All the marked programs are provided
with a program protection - indicated by the * symbol behind the program
number >

Reset program protection

1. - 7. see above

8. Select "Reset Program Protec."

< The program protection of the selected programs is deleted >

K5A - 34
5.0 Automatic Operation
Continuation Program Directory: Set / Reset Program Protection

Set program protection (XT model) Marking

1. Press the "Program Directory" touch key

2. Select Memory segment A or B with touch key "Memory selection"

3. Press the touch keys "Input ON" + "Marking"

Select (mark) the program number(s) to be protected or input them via

num. keypad (e. g.: 1 ,3 , etc.)

4. Press the "Set Program Protec." touch key

< Program directory is displayed. All the marked programs are provided
with a program protection - indicated by the * symbol behind the program
number >

Reset program protection

1. - 3. as above-mentioned

4. Select "Reset Program Protec."

< The program protection of the selected programs is deleted >

Set Program Protection +
Reset Program Protection

K5A - 35
 5.0 Automatic Operation
Inserting of Measurements into a Program

1. Select desired program X model

2. Select step that will receive new measurement

3. X model: press key "Insert"

XT model: press touch keys "Input Mode On" + "Insert"

4. Enter measurement

5. X model: press key "Enter"

XT model: as on X, or press the "Trigger function" touch key

XT model

K5A - 36
5.0 Automaitc Operation
Storing of Measurements According to Printed Image

1. X model: press key "Actual to Nominal Position" X model

XT model: press touch key "Actual to Nominal Position"

< actual size appears in input section

Operation display: ACTUAL > NOMINAL POSITION >

2. Align stock at backgauge

3. Adjust backgauge by handwheel to correct cut position

(use optical/mechanical cutting line indicator)

4. X model: press key "Enter"

XT model: as on X, or press the "Trigger function" touch key

XT model
Switch off function

Press key/touch key "Actual to Nominal Position" again

When the automatic function is activated switching off the Actual to Nominal
Position is done automatically!

K5A - 37
 5.0 Automatic Operation
Compensation of Variations in Print (78 XT - 176 XT)

Application: Slight shifting of printed image on sheet due to

stretching or shrinking.
For nominal measurements and Eltrotact cut sequences

There are two possible variations:

A Distorsion correction in Automatic mode via hand wheel

B Distorsion correction via knob "Distorsion Correction"

Turning knob "Distorsion Correction",

A Distorsion correction in Automatic mode via hand wheel Correction value, min. : 0,05 mm

1. Press touch key "Automatic On"

2. Move to size and check cut position (opt./mech. cutting line indicator)
3. Set amount for compensation by hand wheel
4. Check cut position again (opt./mech. cutting line indicator) and make cut
Distortion appears in size display. Automatic function is not switched off!

5. Select "Save YES or Save NO" and store with key "Enter"

B Distorsion correction via knob "Distorsion correction"*

1 + 2. as above-mentioned

3. Set amount for compensation by turning knob "Distorsion Correction"

< value appears in size display (expansion) >

4. Press key twice (positioning) or press touch key "Trigger func-

tion" < Backgauge moves to compensated size >

5. Check cut position again (opt./mech. cutting line indicator) and make cut

6. Select "Save YES or SAVE NO" and store with key "Enter"

** A correction value adjusted by means of turning knob "Distorsion Correction"

must be moved to in any case. Otherwise, no correction value can be transferred!

K5A - 38
5.0 Automatic Operation
Calculator Functions

Conditions: Automatic OFF To store results in calculator memory:

The digital and calculator keys enable 4 basic arithmetic operations. Press key/touch key (Contents of memory is displayed above the input
They can be used to calculate cut sizes. section)
The calculation and the solution are always displayed in the input section.
Please note: To recall values onto the display:
On XT models, the numerical keypad can be superimposed on the display
(see page E - 10) Press key/touch key

To set backgauge to a calculated size: Example (condition: Automatic OFF):

Press key twice shortly Key operation:

To store this size: 15,000

Press key "Enter" (15,000)

14,000
Overflow indicator

If the solution of a calculation exceeds 999.999 (15,000) 29,000

< A beep will sound; mode display: DIGIT OVERFLOW >

Delete memory display together with stored value: Actuate key

Remedy: 1. Clear last input by pressing
2. Enter new figure

To clear total input:

Press key three times

K5A - 39
 5.0 Automatic Operation
Negative Sign

Negative result of a calculation

< Minus " - "sign appears before number in input section >

If this result is a cutting size the negative sign needs to be deleted

Press key < " - " sign disappears >

Using Backgauge Position of Calculations

If you have set the backgauge to a cut size on a printed sheet and you want to
use this for further calculations:

Press key/touch key "Actual to Nominal position"

< Actual size appears in input section >

Possible arithmetic operation (actual size = backgauge position):

e.g.: actual size (backgauge position): 49,996 cm less 10,000 cm

Entry: 1. < actual position 49,996 appears in input section >

2. (49.996)

Result: 39,996

Store the result or position backgauge!

Switching this function off: Press key/touch key again or press key
Automatic On

K5A - 40
5.0 Automatic Operation
Cut Correction

Use: Works only in ELTROTACT mode!

To compensate for stretching or shrinking of sheet

Condition: • Automatic operation ON

• Cursor marks a label size; Turning knob "Distorsion Correction",
• Label size must be moved to Correction value, min.: 0,01 mm

Adjust correction value

1. Turn knob "Cut Correction"

< correction value is displayed in correction section >

2. Positioning: press key twice*.

3. Make cut

Attention!
The amount of correction will be added to each cut on repeat sequence

Resetting correction:

Automatically with backgauge reverse; amount of correction is automatically set

back to zero.

* A correction value adjusted by means of turning knob "Distorsion Correction"

must be positioned for the next cut in any case. Otherwise, correction is done
with the next measurement!

K5A - 41
K5A - 42
5.0 Automatic Operation
Machine Functions and Additional Functions (Menu Keys)

Machine Functions X model

4 6
Machine functions are basic functions of the machine. They can be changed for
the program sequence.
The machine functions can be selected by pressing one of the following
pushbuttons/touch-keys: D
Main Menu (1) (page K5B - 2)
5 i 2
Auxiliary Functions (2) (page K5F - 1) 3
1

Machine Parameters (3) (page K5G - 1)

Additional Functions
7
The running of cutting programs can be further automated by using additional 7 8 9
functions. For this purpose, several multi-function keys/touch-keys in different
categories are available to the user.
XT model
4 5 6
Menu keys: 1 2 3
Additional Functions (4) (page K5C - 1)
C 0
Program Functions (5) (page K5D - 1)

External Additional Functions (6) (page K5E - 1)

User Defined Additional Functions (7) (page K5H - 1)

1
By pressing any of the menu keys / menu touch keys, you can open a sub-menu
which gives access to various additional functions.
The corresponding sub-functions can be activated by selecting the correspon-
ding code number of the pictograph (X model) or by actuating the line (XT
model). They can be transferred to the currently selected program.
A stored additional function is represented as a pictograph in the "Program Data"
menu, behind the cut size. It is possible to store several additional functions
together with one step number.
4 6 5 2 7 3

K5B - 1
 5.0 Automatic Operation
Main Menu (Function Survey)

Key/touch-key "Main Menu" X model

D

Key/touch.key "Main Menu" includes the following functions*: i

78X/XT 92X/XT 115X/XT 137X/XT 155X/XT 176X/XT

Program Functions:
Language x x x x x x
Measuring unit x x x x x x
Copy program x x x x x x
Block programming x x x x x x
Production report x x x x x x XT model
Sheet size tables x x x x x x

Machine Functions:
Service x x x x x x
Knife change/Correction x x x x x x
Maintenance cut counter x x x x x x
Preset cut counter x² x² x² x² x² x²
Press material x x x x x x
Preset functions:
Machine setup x x x x x x
Setup program functions x x x x x x
Setup serial interface x x x x x x
Setup production report x x x x x x
Press material x x x x x x
Correction for material x² x² x² x² x² x²

x Function available
x² only on XT machines

Note!
You can switch over from the "Program Functions" to the "Machine Functions"
side and vice versa,
on X models:
• by actuating the cursor keys right/left o r
• using the "0" key on the numerical keypad
on XT models:
• by touching the function side
• by actuating the "Cursor" touch keys
* Technical alterations reserved

K5B - 2
5.0 Automatic Operation
Main Menu: Language

Select the function:

1. Select "Language" *

< selection menu is displayed >

2. Make selection (e.g. ENGLISH - GB -)

After this selection has been made all displays are shown in the language
selected.

* The asterisk always identifies the operation "Select Language". This facilitates
the selection of this operation when function survey is displayed in a foreign
language.

-----------------------------------------------------------------------------------------------------------

Main Menu: Measuring Unit

Select function "Measuring unit": **

1. Select "Measuring unit" < menu appears >

2. Select dimension e.g. centimeters

** The "Measuring unit" menu can be picked by

touching the measuring unit display in the
"Program Data" menu!

K5B - 3
 5.0 Automatic Operation
Main Menu: Copy Program*

Select "Copy program" **

Condition: efficient memory capacity (free programs/spaces)

Copying methods:

A. Copy a program within memory segment A or B

B. Several programs within the memory segment

C. A program from memory segment A or B, resp., to memory

segment B or A, resp.

D. Several programs from memory segment A or B, resp., to

memory segment B or A, resp.

E. Complete contents of memory segment A or B, resp., to

memory segment B or A, resp.

* Only up to program version V1.2.2

** Program version V1.2.3. The programs copied in the "Program Directory"
menu (see page K5A-32).

K5B - 4
5.0 Automatic Operation
Copy a Program Within Memory Segment A or B, Resp.*

Example: Program 4A into 35A

1. Select "from memory seg. A"

< Program Directory of memory A appears;

Input section reads: ENTER SOURCE PROG-NO >

2. Enter "source program-no.", e.g.: 4

3. Select "to memory seg. A"

< Program Directory of memory A appears;

Input section reads: ENTER DESTINATION PROG-NO:

A free program is being offered!

If the free program is to be accepted as a target program:

X model: press key "Enter"

XT model: as on X, or press the "Trigger function" touch key

or

enter desired program number, such as e.g.: 35

Program Directory appears: end of copying.

Sizes and comments of the copied program are now stored in program no.
35, too.

Note!
If the target program number is not free:

beep sounds and display shows "program no. not vacant"

*Only up to program version V1.2.2

K5B - 5
 5.0 Automatic Operation
Copy Several Programs Within Memory Segments A or B, Resp.*

Example: programs 1 - 25 into program 50 - 75

1. Select "from memory seg. A"

2. Enter: "source program no.", e.g.: 1 - 25 *

or

3. Select "to memory seg. A"

4. Enter "target program no.", e.g.: 50 - 75

< Sizes and comments of programs 1 through 25 are now stored in

50 through 75 too >

* It is possible to enter a maximum of 7 unarranged program numbers

(such as e.g., 2. 5. 7. 9. 11. 13. 18.)!
The individual program numbers must be separated by decimal points.
*Only up to program version V1.2.2

Copy a Program/Several Programs From Memory Segment A or B, Resp., to Memory Segment B or A, Resp.*
Same input mode as with "copying one/several programs within memory
block"

except

3. (!) Select "into memory seg. B"

< Program Directory of memory B appears >

*Only up to program version V1.2.2

K5B - 6
5.0 Automatic Operation
Copy the Complete Contents of Memory Segment A or B, Resp., to Memory Segment B or A, Resp.*

1. Select "from memory seg. A"

2. Enter "source prog. no.", e.g.: 1 - 999

3. Select "to memory seg. B"

4. Enter "target program no.", e.g.: 1 - 999

< complete data of memory A are transfered into memory B.

Even protected programs are copied with protection! >.

*Only up to program version V1.2.2

K5B - 7
 5.0 Automatic Operation
Main Menu: Block Programming

Select "Block Programming"

Block programming = automatic programming

Block programming is fitted with graphic operator prompting for the automatic
generation of a cutting program for printed and unprinted sheets.
Input of initial sheet size, outside trim, labels and trim cuts can be made by entry via
keypad (XT: superimposed numerical keypad!) or by approaching with the backgauge.
The required cutting sizes and remarks are automatically stored in a free program.
During the automatic processing of the graphic program, a process visualization is
started which graphically represents every single program step.

Setting up a block program

Example 1: unprinted sheet, initial sheet size 31 x 43 cm; angular trim

1. Select menu "Orig. Sheet (Lay Guide)" : menu 1. Left side*

2. Right side
3. Continue block
programm.
2. Select "Continue block programm."

3. Menu: 1. DIN sheet sizes A (0 - 9)

2. Standard sizes (0 - 9)
3. Original sheet size

4. Select "Original sheet size" (XT: superimpose num. keypad?)

5. Enter "Original sheet size X" (43 cm)

6. Enter "Original sheet size Y" (31 cm)

7. Menu: 1. Interch. X/Y of orig. sheet**

2. Interchange every X and Y***
3. Contimue block programm.*
* is preset
8. Select "Continue block programm." ** dimensions X and Y of the original sheet are interchanged
*** "original sheet size" and "final size" are interchanged simultaneously

K5B - 8
5.0 Automatic Operation
Continuing Main Menu: Block Programming

9. Enter "Edge trim width X" (0,5 cm)

10. Enter "Edge trim width Y" (0,5 cm)

11. Menu: 1. Continue block programm.*

2. Four edge trim
3. Angular trim

12. Select "Angular trim"

13. Store program with key "Enter"

Order menu:

14. Menu: 1. Modify order

Copy program to:
2. Memory seg. A/B
3. Program number
Finish entry

Selection 1**: How to change the order name Before doing so, delete the
default text at

X model: by pressing key ;

XT model: by means of the "Delete" touch key on the keypad
enter new program name; confirm with key

Selection 2: select target memory "A" or "B"

Selection 3: Change the recommended program number and enter the

desired program number. If the program is already allocated, a
message is shown on the display.

Finish entry with key "Finish entry" (= Enter)

< The Program Data menu with graphics is indicated >

* is preset
** the alphabetic keypad is superimposed

K5B - 9
 5.0 Automatic Operation
Continuing Main Menu: Block Programming

Example 2: unprinted sheet, initial sheet size 31 x 43 cm; four edge trim

1. Select menu "Orig. Sheet (Lay Guide)" : menu 1. Left side*

2. Right side
3. Continue block programm.
2. Select "Continue block programm."

3. Menu: 1. DIN sheet sizes A (0 - 9)

2. Standard sizes (0 - 9)
3. Original sheet size

4. Select "Original sheet size" (XT: superimpose num. keypad?)

5. Enter "Original sheet size X" (43 cm)

6. Enter "Original sheet size Y" (31 cm)

7. Menu: 1. Interch. X/Y of orig. sheet **

2. Interchange every X and Y ***
3. Continue block programm. *

8. Select "Continue block programm."

9. Enter "Edge trim width X" (0,5 cm)

10. Enter "Edge trim width Y" (0,5 cm)

11. Menu: 1. Continue block programm.

2. Four edge trim
3. Angular trim

12. Select "four edge trim"

13. Store program with key "Enter"

* is preset
** dimensions X and Y of the original sheet are interchanged
*** "original sheet size" and "final size" are interchanged simultaneously

K5B - 10
5.0 Automatic Operation
Continuing Main Menu: Block Programming

Order menu:

14. Menu: 1. Modify order

Copy program to:
2. Memory seg. A/B
3. Program number
Finish entry

Selection 1*: How to change the order name Before doing so, delete the
default text at

X model: by pressing key ;

XT model: by means of the "Delete" touch key on the
keypad.
Enter new program name; confirm with key

Selection 2: select target memory "A" or "B"

Selection 3: Change the recommended program number and enter the

desired program number. If the program is already allocated,
a message is shown on the display.

Finish entry with key "Finish entry" (= Enter)

< The Program Data menu with graphics is indicated >

* the alphabetic keypad is superimposed

K5B - 11
 5.0 Automatic Operation
Continuing Main Menu: Block Programming

Example 3: unprinted sheet, initial sheet size 61 x 86 cm; required size DIN
A4, optimum yield

1. Select menu "Orig. Sheet (Lay Guide)" : menu 1. Left side*

2. Right side
3. Continue block programm.

2. Select "Continue block programm."

3. Menu: 1. DIN sheet sizes A (0 - 9)

2. Standard sizes (0 - 9)
3. Original sheet size

4. Select "Original sheet size" (XT: superimpose num. keypad?)

5. Enter "Original sheet size X" (86 cm)

6. Enter "Original sheet size Y" (61 cm)

7. Menu: 1. Interch. X/Y of orig. sheet **

2. Interchange every X and Y ***
3. Continue block programm. *

8. Continue block programming

9. Enter "Edge trim width X" (0,5 cm)

10. Enter "Edge trim width Y" (0,5 cm)

11. Menu: 1. Continue block programm.*

2. Four edge trim
3. Angular trim

12. Select "Continue block programm."

* is preset,
** dimensions X and Y of the original sheet are interchanged
*** "original sheet size" and "final size" are interchanged simultaneously

K5B - 12
5.0 Automatic Operation
Continuing Main Menu: Block Programming

13. Menu: 1. DIN sheet sizes A (0 - 9) * Note:

2. Standard sizes (0 - 9)
3. Required size items 1+2:
Program generation with absolute measures offers the advantage that cut sizes
14. Select "DIN sheet sizes" can be corrected more easily. However, the program volume is much bigger
than upon generation with Eltrotact.
15. Select e.g. size "DIN A 4"
item 3:
16. Menu: 1. Sheet orientation Deletion of all input data of current block programming
2. Optimize (No. of sheets)
3. Trimouts
4. Cut sequence item 4.
Scroll program with cursor keys for data input
17. Select "Optimize (No. of sheets)"

18. Store program with key "Enter"

After storing of program, a program generation selection is made. Two

generating procedures are available:

1. Generate program with Eltrotact (PROG. GEN. WITH ELTROTACT)

2. Generate program with absolute measures (PROG. GEN. ABS.
VALUES)
3. Clear all input data
4. Return to input

Select e.g. PROG. GEN. WITH ELTROTACT

Order menu:

19. Menu: 1. Modify order

Copy program to:
2. Memory seg. A/B
3. Program number
Finish entry

K5B - 13
 5.0 Automatic Operation
Continuing Main Menu: Block Programming

Selection 1*: How to change the order name Before doing so, delete the
default text at

X model: by pressing key

XT model: by means of the "Delete" touch key on the
keypad.
Enter new program name; confirm with key

Selection 2: select target memory "A" or "B"

Selection 3: Change the recommended program number and enter the

desired program number. If the program is already allocated,
a message is shown on the display.

Finish entry with key "Finish entry" (= Enter)

< The Program Data menu with graphics is indicated >

* the alphabetic keypad is superimposed

K5B - 14
5.0 Automatic Operation
Continuing Main Menu: Block Programming

Examplel 4: Block trimming, initial sheet 61 x 86 cm; required size DIN A4,
29,7 x 21 cm

1. Select menu "Orig. Sheet (Lay Guide)" : menu 1. Left side*

2. Right side
3. Continue block programm.

2. Select "Continue block programm."

3. Menu: 1. DIN sheet sizes A (0 - 9)

2. Standard sizes (0 - 9)
3. Original sheet size

4. Select "Original sheet size" (XT: superimpose num. keypad?)

5. Enter "Original sheet size X" (86 cm)

6. Enter "Original sheet size Y" (61 cm)

7. Menu: 1. Interch. X/Y of orig. sheet **

2. Interchange every X and Y ***
3. Continue block programm. *

8. Continue block programming

9. Enter "Edge trim width X" (0,5 cm)

10. Enter "Edge trim width Y" (0,5 cm)

11. Menu: 1. Continue block programm. *

2. Four edge trim
3. Angular trim

12. Select "Continue block programm."

13. Menu: 1. DIN sheet sizes A (0 - 9)

2. Standard sizes (0 - 9)
3. Required size * is preset, ** dimensions X and Y of the original sheet are interchanged
*** "original sheet size" and "final size" are interchanged simultaneously

K5B - 15
 5.0 Automatic Operation
Continuing Main Menu: Block Programming

14. Select "Required size" * Note:

15. Enter "Final size X" items 1+2:

Program generation with absolute measures offers the advantage that cut sizes
16. Enter "Final size Y" can be corrected more easily. However, the program volume is much bigger
than upon generation with Eltrotact.
17. Menu: 1. Sheet orientation
2. Optimize (No. of sheets) item 3:
3. Trimouts Deletion of all input data of current block programming
4. Cut sequence

18. Select "Trimouts" item 4.

Scroll program with cursor keys for data input
19. Enter "Trimouts X"

20. Enter "Trimouts Y"

21. Input "Sequence without trimouts"

22. Enter "Sequ. without trimout X"

23. Enter "Sequ. without trimout Y"

24. Select cut sequence 1. Lengthwise

2. Crosswise
3. Crosswise1

Select e.g.: Lengthwise

store program with key "Enter"

After storing of program, a program generation selection is made. Two ge-

nerating procedures are available:

1. Generate program with Eltrotact (PROG. GEN. WITH ELTROTACT)

2. Generate program with absolute measures (PROG. GEN. ABS.
VALUES)
3. Clear all input data
4. Return to input

K5B - 16
5.0 Automatic Operation
Continuing Main Menu: Block Programming

Select e.g.: PROG. GEN. WITH ELTROTACT

Order menu:

25. Menu: 1. Modify order

Copy program to:
2. Memory seg. A/B
3. Program number
Finish entry

Selection 1*: How to change the order name Before doing so, delete the
default text at

X model: by pressing key ;

XT model: by means of the "Delete" touch key on the
keypad.
Enter new program name; confirm with key

Selection 2: select target memory "A" or "B"

Selection 3: Change the recommended program number and enter the

desired program number. If the program is already allocated, a message is
shown on the display.

Finish entry with key "Finish entry" (= Enter)

< The Program Data menu with graphics is indicated >

* the alphabetic keypad is superimposed

K5B - 17
5.0 Automatic Operation
Selection of an Input Parameter with Block Programming

Keep pressing the cursor keys or cursor touch keys, until the desired input
parameter is indicated in the input section.

Correction of an Input Parameter with Block Programming

1. Select desired parameter

2. Enter new size (old size is erased)

3. Press key < new size is displayed >

4. Continue selection procedure

5. Store block program by pressing key "Enter"

Program visualization of a graphic program

Simulation of the program run in automatic operation.

The program run of a graphic program can be simulated graphically by pressing

the backgauge motion key "Backgauge movement: slow advance".
Each time the key is pressed, label group by label group, or label by label will be
graphically processed. The cutting line is indicated by a line. The cut section is
highlighted so that it stands out from the remaining sheet.

K5B - 18
5.0 Automatic Operation
Main Menu: Production Report

The production report lists up the production data and, at the same time, records
the different times required for production and for setting of a program, main-
tenance, pauses etc.

To start the production report:

• Set time and date (see page K5B-30)
• Categorization of production -/interruption times (see page "Preset
functions" page K5B-36)
A
Select Production report

1. Select "Main Menu" or - on XT model - simply touch the line (A) in

Program Data menu

2. Select "Production Report"

Starting procedure of Production Report Note:

When the production report appears in the sections ORDER FINISHED and
1. Select "(0) Order start" DATE the data of the previous (if any) are displayed. After the starting proce-
< Time memory T1* is automatically activated (lit up) > dure for the production report ORDER FINISHED changes to ORDER START
and actual time and date are set automatically.
2. Select desired operation (e.g. setting of program in Program Data menu)
or
- select another time memory (T2-T7) Selection "(10) Start / Leave":
or
- fill in production report (select Pos. 10 -21) Select "Start or Leave", respectively.

In the selected time memory (T1-T7) the time required for all subsequent opera- Once the production report has been started, an identification of the operating
tions is recorded and stored as long as this time memory is selected. An activat- staff can be carried out by selecting item "10").
ed production report is shown in the program heading of the Program Data menu. All the operators can be selected from a list, whose names have been previ-
ously entered in the "Preset Functions" menu – item "Setup Production Report"
Back to Program Data menu: – item "Define Operators". By entering the code number, the name is trans-
ferred.
Press key/touch key "Automatic On" or "Program Data" menu As soon as an operator has been selected and the Program Information
menu started, a pop-up window is displayed that indicates the current
operator data.

* Time memory T1 should always be used for "Production". For interruptions of the production
another time memory (T2-T7) has to be selected.

K5B-21
 5.0 Automatic Operation
Continuing Main Menu: Production Report

Entering data into a production report (items 10 - 21) * "Order readout" is merely an indicator display!

Precondition: "(0) Order start" selected The following items are indicated:

The time required for filling in the production report is stored in the actually activated • Recording of the individual interrupts (timing pulse storage)
interruption category (time memory T1-T7)). • Order - Total time required
• Number of cuts performed.
Filling the lines:

1. Select desired item (10 - 21) Note:

2. Enter the information The production report is printed out automatically when it is terminated by
selection of "(0) ORDER FINISHED". If no printer is connected, the follow-
3. Actuate button "Enter" ing information is displayed: No device assigned!

"(8) Display Order"*

1. Select "Display order" in input section: (1) Previous

(2) Present

Previous = display of the previous production report

Present = display of the actual production report

2. Make selection
To return to production report press button X-model:
XT-model: "Return"

"(9) Print Order"

1. Select "Print Order"

2. Select: (1) Previous

(2) Present

When selected, complete production report with time indication (Order readout) is
printed out.

To return to main menu press button X-model:

XT-model: "Return"

K5B-22
5.0 Automatic Operation
Main Menu: Sheet Size Tables

The menus indicated below are pure information menus. They are not connected
to any other screen forms.
No values can be entered nor selections be made.

DIN sheet sizes A (0 - 9) / DIN sheet sizes B (0 - 9)

The menu indicates a list of dimensions of these two DIN sheet size classes.

JIS sheet sizes B (0 - 9)

List of dimensions of Japanese JIS sheet sizes.

Sheet offset sizes (0 - 9)

List of sheet offset sizes with classification of the corresponding printing machine
size.

Inch sheet sizes (0 - 9)

List of inch sheet sizes in inches and in metrical system, respectively.

Standard sizes (0 - 9)
Standard sizes are only indicated in the menu provided that the corresponding
sizes have been input and stored in menu "Preset Functions", sub-menu
"Standard Sizes (0 - 9)"

To return to main menu press...: X model: key

XT model: touch key "Return"

Main Menu: Service

Display of machine identification type plate (see page K3-3).
The function "Service" is only accessible to POLAR service or its agencies.
Access only after entering a code number.

K5B-23
 5.0 Automatic Operation
Main Menu: Knife Thickness Compensation

Calibration to compensate for knives of different thickness

Select "Knife Change / Correction"

Selection "Position Correction for Knife":

As soon as the mask "Knife Change / Correction" has been selected, the current
compensation value of knife thickness is displayed next to the knife thickness
pictograph. The mask also show a survey of all compensation values of the
machine.
To enter another correction value, a previously stored knife thickness value can
be selected from a list previously generated by the user (see "Preset Functions",
page K5B-37). This list can take up a maximum of 27 knives with their respective
compensation values.

Example:
All the knives that belong to the machine, are numbered and measured after they
have been ground.
Consult your knife grinder. He will certainly note down the corresponding knife
thickness compensation values (deviation from original size) of the respective
knife; either in an accompanying document or on the knife itself. Enter these
compensation values into the knife thickness list under the respective knife
number (#). After a knife change, you can select the corresponding knife.

Transfer knife compensation value as an actual value:

1. Select desired position number

< value for knife (thickness) correction is indicated on the selection

screen >

To quit menu, press key X model:

XT model: touch key "Return"

K5B-24
5.0 Automatic Operation
Main Menu: Maintenance Cut Counter

Operation: Shows maintenance intervals.

Has been set to 100.000 cuts by manufacturer.

Counter starts at "0" or other preset amount and counts upward. After reaching
100.000, at every start-up, the operation display will read OBSERVE
MAINTENANCE SCHEDULE

Selection:

Set counter

1. Enter number of cuts via numerical keypad

2. X model: press key "Enter"

XT model as on X, or press the "Trigger function" touch key

Enter remarks

1. Enter remarks via inserted alpha keypad

2. X model: press key "Enter"

XT model: as on X, or press the "Enter" touch key on the alphabetic
keypad

Deletion of a remark:
Remarks can only be deleted by the line!

X model:
1. Position the input cursor on the first character in the line

2. Press the "Delete" and "Enter" keys

XT model:
1. Position the input cursor on the first character in the line using the keys
(< , >) of the alphabetic keypad
2. Press the "Delete" touch key on the alphabetic keypad
3. Actuate the "Enter" touch key on the alphabetic keypad

To leave the menu: X model: Press key

XT model: Press the "Return" touch key

K5B-25
 5.0 Automatic Operation
Main Menu: Preset Cut Counter (XT)

Application: e.g. to find knife life

The preset cut counter counts backwards from set amount down to "0". When
counter is back at zero, operation display will read, after each start-up of automatic
mode QUANTITY OF CUTS COMPLETE. At the same time a beep sounds.

Select:

Set value of counter

1. Enter value via numerical keypad

2. Press key "Enter" or press the "Trigger function" touch key

Activate counter Yes/No

Enter remarks

1. Enter remarks via inserted alpha keypad

2. Press key "Enter" or press the "Enter" touch key on the alphabetic
keypad

Deletion of remarks:
Remarks can only be deleted by the line!

1. Position the input cursor on the first character in the line using the keys
(< , >) of the alphabetic keypad

2. Press the "Delete" touch key on the alphabetic keypad

3. Actuate the "Enter" touch key on the alphabetic keypad

K5B-26
5.0 Automatic Operation
Main Menu: Preset Functions

The menu "Preset Functions" is subdivided into the following menus:

1 Machine Setup
Available sub-menus: Search reference position / Aux. mode
Correction of current position

2 Setup Program Functions

Available sub-menus: Set time/date
Standard sizes (0-9)
User defined comments
External additional functions*
Sort index cards*
Configure air push button*
Air off using foot pedal
Align: Ignore light barrier*
PL-block branch table*

3 Standard version: Setup Serial Interface

With DBR board (optional): Setup Production Report

4 Standard version: Setup Production Report

With DBR board (optional): Authorize services

5 Standard version: Setup Production Control System

With DBR board (optional): Activate services

6 List of knife corrections

7 List of correction for material

* on XT-machines only!

K5B-27
 5.0 Automatic Operation
Continuing Main Menu: Preset Functions

Select menu "Machine Setup

Select function: Search Ref. Pos. / Aux. Operation

In the case of a machine malfunction the reference point can be newly

scanned with this function.

Procedure:

1. Select "Search ref. pos. / Aux. operation" < display change >

2. Confirm "Clear table surface" < display change >

3. Actuate the hand wheel, backgauge movement keys or the "backgauge

movement" touch key

To leave the menu:: Select "Abandon"

Abortion of reference run:

Press key

As soon as the reference run has been terminated, the "Basic measurement -
correction menu" is displayed (see page K5B-29).
The basic measurement must be confirmed or set anew.
After this procedure the Program Data menu will automatically be indicated.

Auxiliary operation without actual position

If no reference point is found during the reference run an auxiliary mode can be
activated (see also page K7-5).

Possible functions in Auxiliary mode:

• Cutting
• Manual displacement of backgauge by means of handwheel or
backgauge movement keys

K5B-28
5.0 Automatic Operation
Continuing Main Menu: Preset Functions

Select menu "Machine Setup

Selection: Correction of Current Position

This menu allows the inspection and correction of the basic measurement (actual
position) of the machine.

If the actual position indicated corresponds to the actual backgauge

position:

Select "Current Position OK"

If the indicated position does not coincide with the actual backgauge
position:

Select "Correct Current Position"

Calculate basic position:

1. Position backgauge at any position (e.g.: 20.5 cm)

2. Feed paper and cut it

3. Place backgauge at smaller size (e.g. 20 cm)

4. Turn paper by 180° and cut again

5. Divide size with "2" (e.g.: 20 : 2 = 10);

move backgauge to measurement and release cut

6. Determine length of part 1 by sliding calliper (e.g. 10.2 cm), enter and store
measured size.

Note: From this display you can activate the auxiliary operation.

K5B-29
 5.0 Automatic Operation
Continuing Main Menu: Preset Functions

Select menu "Preset functions"

Select function: Set Time/Date

Selection: Time

in input section appears - Enter hours

1. Enter hours via numerical keypad

2. Press key

in input section appears - Enter minutes

1. Enter minutes via numerical keypad

2. Press key

in input section appears - Enter seconds

1. Enter seconds via numerical keypad

2. Press keys and "Enter"

Selection: (12/24 <12 or 24 hours display >

In the 24 hours display a selection of this function will initiate a switch-over to a

12 hours display and to an "American" display of date and month. The resp.
indication AM or PM appears automatically.

Selection: AM/PM Display only when 12 hours display selected; switch

over when actuated

Selection: Date same input as with Time, but input of Day, Month, Year.

To get back to initial display "Preset functions":

Press key or touch key "Return"

K5B-30
5.0 Automatic Operation
Continuing Main Menu: Preset Functions

Select function: Standard Sizes (0 - 9)

Under this category often required cut sizes can be stored. They can be trans-
ferred to the block program by entering the code number (0 - 9)

Memory:
Selection (e.g. 0)

in input section: X (0) final size

1. Enter size via numerical keypad

2. X model: press key
XT model: as on X, or press the "Trigger function" touch key

in input section: Y (0) final size - input as above

in input section: Enter remarks < alpha keypad activated >

1. Enter remark with alpha keypad

2. X model: press key "Enter"

XT model: press the "Enter" touch key on the alphabetic keypad

To get back to initial display "Preset functions":

press key or touch key "Return"

K5B-31
 5.0 Automatic Operation
Continuing Main Menu: Preset Functions

Select function: User Defined Comments

The menu makes it possible to store up to 18 frequently used comments. When

this function is selected from the Program Data image the comments will be
displayed in a window and can be transferred to the program.

Storage:

1. Select comment line < alpha keypad is activated >

2. Enter comment with alpha keypad

3. X model: press key "Enter"

XT model: press touch key "Enter" on alpha keypad

_________________________________________________________________

Select function: External Additional Functions

(on XT-machines only!)

Eight external additional functions can be programmed. They are divided into
those functions performed

• prior to positioning (e.g. start transport device) To get back to initial display "Preset functions":
• after positioning (e.g. start gripper) press key or touch key "Return"

The external additional functions are displayed in a window after pressing

key/touch key . They can be transferred directly from the window to the
cutting program.

Storage

1. Select number/line < Alpha keypad is activated >

2. Enter desired text with alpha keypad
3. Press touch key "Enter" on alpha keypad

K5B-32
5.0 Automatic Operation
Continuing Main Menu: Preset Functions

Selection: Sort Index Cards

(on XT-machines only!)

Sort the index cards of additional functions and machine parameters in a

deliberate order.

Possible selections:
• New Configuration
• Default Setting

Selection: New Configuration

This function allows the user to sort the index cards of the "Additional Func-
tions" and the "Machine Parameters" menu in any order desired.
Always sort all the additional functions or parameters!

Procedure:

1. Select desired additional function/parameter

2. Select the desired position number to which the function is to be as-

signed.
< all the functions assigned are displayed on the right side under the
selected function number>.

Once all the additional functions or parameters have been positioned:

3. X model: press key "Enter"

XT model: as on X, or press the "Trigger function" touch key

The input can be corrected by pressing the touch key "Correction" or

"Delete".

Selection "Default Setting"

If the new configuration is to be rejected, return to the factory setting by using the
"Default Setting" function.

K5B-33
 5.0 Automatic Operation
Continuing Main Menu: Preset Functions

Selection: Configure Air Push Button

(on XT-machines only!)

By this function the manual air push button beneath the front table can be se-
lected in two different configuration variants.

1. first hit of the key: front table air supply ON

second hit of key: whole table air supply ON

2. first hit of the key: rear table air supply ON

second hit of key: whole table air supply ON

_________________________________________________________________

Selection: Air Off Using Foot Pedal

Selection: Yes / No
Cut - off activated air supply to table surface by actuating foot pedal

_________________________________________________________________

Selection: PL-Block Branch Table

(on XT-machines only!)

Selection: Yes/No
Display of auxiliary-function index card "PL-block branch table" for the
indication of the individual program-loop blocks of a program.

K5B-34
5.0 Automatic Operation
Continuing Main Menu: Preset Functions

Standard version:

Selection: Setup Serial Interface

In this menu device attachments can be assigned to the second interface of the
CP2 board of the control system.

The following device attachments can be assigned:

1 Printer
2 Compucut
3 Autocut
4 Service-PC

To get back to initial display "Preset functions":

press key or touch key "Return"

Version with optional "DBR board":

Selection: Authorize services (P-Net)*

1 No Prod. Control

2 CutManager(Option)
Automatic acquisition of operational data through CutManager allows to
access a wide range of production data.

3 Compucut (Option)
Modular POLAR software system.
External generation of cutting programs through automatic data transfer
from the prepress stage (CIP 3 and CIP 4)

4 Remote Diagnosis (Option)

On-line inspection and remote diagnosis of high-speed cutters.

to be continued on next page

K5B-35
 5.0 Automatic Operation
Continuing Main Menu: Preset Functions

5 Ext. Prog. Memory

(ESPV cutting program management with P-Net*)
Storage of a deliberate number of cutting programs on the central P-Net
Server. In addition, P-Net organizes fast and efficiently the exchange of
programs between the cutting machines which are connected to the
network.
In this way, mobile data media, such as floppy disks or flash cards are no
longer required.

6 CFC
Central Function Control via P-Net*

Selection: Activate services (P-Net)*

Input of machine identification and authorization code for the requested service.

To get back to initial display "Preset functions":

press key or touch key "Return"

* P-Net is an Ethernet-compatible network connection with a central server. Data

can be easily transferred via TCP-IP technology between the P-Net Server and
the connected components.
The "P-Net" allows to link POLAR high-speed cutters with POLAR peripheral
equipments. So: The complete workflow of a cutting system can be controlled
from the control console of the high-speed cutter!
As the central interface of communication of a high-speed cutter within a cutting
system the "P-Net" forms a network that meets the most versatile present and
future demands.

K5B-36
5.0 Automatic Operation
Continuing Main Menu: Preset Functions

Selection: Setup Production Report

Input of categorization (names) for production-/ interruption times (time assign-

ments) in time memories T1 - T7 for production report and preadjustment of
operating personal.

Storage "Define Time Assignments"

e.g.: T1 Production*

1. Select "Define Time Assignments"

2. Select T1 < alpha keypad is activated >
3. Enter "Production" via alpha keypad

4. X model: press key "Enter"

XT model: press touch key "Enter" on alpha keypad

The stored categories are transferred to the production report.

* Time memory T1 should always be assigned to "Production" as this time

memory counts the number of performed cuts (total number of cuts).

Storage "Define Operators"

1. Select desired list number (1 - 9) < Alpha keypad is activated >

2. Enter first name **
3. Enter second name**
4. Enter personal number**
5. Enter shift**

** X-Model: confirm with key

** XT-Model: confirm with touch key "Trigger function"

6. Store input by pressing "Enter" key .

K5B-37
 5.0 Automatic Operation
Continuing Main Menu: Preset Functions

Selection: List of Knife Corrections

In this list, a maximum of 27 knives can be stored together with their re-
spective compensation values. A stored knife compensation value can be
taken as a basic measurement compensation (see also page K5B - 27,
"Position correction due to knife").

1. Select position no. (1 -. 9)

2. Enter knife no. (max. two-digit)

X model: confirm with key
XT model: confirm with touch key "Trigger function"

< Alpha keypad is shown minimized in the display. Maximize alpha keypad! >

3. Enter text (knife description) and confirm it

4. X model: Adjust knife compensation value by "+" or " - " keys of num.
keypad, resp., confirm value by key
XT model: set value by means of touch keys "+"or " - " (in input
section!) and confirm with "Trigger function" touch key

5. Store entries by pressing key "Enter"

________________________________________________________________

Selection: Correction for Material

(on XT-machines only!)

A list of 27 material designations with different correction values. These

compensation values can be transferred as basic correction of position To leave the menu: X model: Press key
(see K5B - 42 "Correction for Material"). XT model: Press the "Return" touch key
A correction for material in the list is stored in the same manner as the storage of
data in the knife thickness list (see above).

K5B-38
5.0 Automatic Operation
Main Menu: Press Material (Fix Clamp)

This function makes it possible by the foot lever to fix the clamping bar on the
material to be cut after having been lowered.

Procedure

1. Make selection "Press Material"

2. Lower clamp onto material to be cut by means of pedal

3. Press any arbitrary numeric key

< clamp is fixed >

Press material with preadjusted clamping pressure:

Press both cut buttons; release after approx. 2 seconds

Terminate fixing (release clamp):

Press any arbitrary numeric key
< clamp moves to upper resting position >

To quit menu, press key or press touch key "Return".

K5B-39
 5.0 Automatic Operation
Main Menu: Correction for Material (XT)

From a list previously stored under the function "Preset functions", different
correction values for the materials can be selected. This concerns materials that
require a correction of basic measurement before they are cut / processed.

A selected material correction value is indicated in the Program Data Display on

the right of the actual position, fitted with a "/+" or */-".

Selection of a compensation value:

1. Select "Correction for Material"

2. Select the number/line of the appropriate material

< Program Data menu is displayed; measurement indication has been

changed by the compensation value. The sign "/+" or "/-" is indicated next
to the position > .

Please note!
Every time the machine is switched on and upon every program change a
pop-up window that indicates the compensation values is displayed in the
Program Data Menu.

K5B-40
5.0 Automatic Operation
Menu Key: Additional Functions

Key/Touch-key "Additional Functions" X model XT model

Key/touch-key "Additional Functions" includes the following operations*:

78X/XT 92X/XT 115X/XT 137X/XT 155X/XT 176X/XT

D
Automatic knife active x x x x x x
Automatic knife prepared
Clamping without cutting
x
x
x
x
x
x
x
x
x
x
x
x i
Jogging mark x x x x x x
Air supply front table ON - - • • x x
Air supply complete
air table ON x x x x x x
Air supply complete
air table OFF x x x x x x
Step parameter x² x² x² x² x² x²
Autotrim waste - - •² •² •² •²
Autotrim align material - - •² •² •² •²
AT. label pusher - - •² •² •² •²
Backgauge advance, slow x² x² x² x² x² x²
Lay guide I x² x² x² x² x² x²
Lay guide II x² x² x² x² x² x²
Align material x² x² x² x² x² x²
Clamp unit at knife** - - •² •² •² •² The running of cutting programs can be further automated by using Additional
Automatic ejector OFF x² x² x² x² x² x² Functions.
Swivel backgauge - - •² •² •² •²
Tilting backgauge - - •² •² •² •² The Additional Functions can be selected on the operating panel/touch-screen
Fixomat - - •² •² •² •² under key/touch key "Additional Functions". The respective pictograph next
Retractable side gauge - - •² •² •² •² to the function identifies the additional function in the program data menu
Clamp unit at backgauge - - •² •² •² •² behind the cut size. It is possible to store several additional functions under
TwinClamp - - •² - - -
_____________________________________________________________________________________ one step number. The order of the index cards shown in the displays can be
changed upon the operator’s desire.
EasyMode x² x² x² x² x² x² When an additional function is stored together with a nominal size, or a
_____________________________________________________________________________________ program step is corrected by one or more additional functions stored, an
Functions, manual controlled: "Additional functions window" will be opened in the Program Data menu after
Lift with semi-automatic the menu key / touch key has been pressed. The window shows all additional
height control - - • • • • functions in plain text together with their corresponding pictographs.
For each step it is possible to store special step parameters (e.g. pressure
- Function not available;
x function available; range, prepressing time etc.).
x² only on XT machines;
•2 optional equipment, only on XT machines; EasyMode is a streamlined programming mode for setting up programs on
• optional equipment XT machines. EasyMode allows to show all of the pictographs of the program-
* Technical alterations reserved mable additional functions in the Data Menu program in order to ensure an
** only on Autotrim machines efficient program generation.

K5C-1
5.0 Automatic Operation
Storage of Additional Functions with Cut Size

1. Enter cut size X model

2. Press key/touch-key "Additional Functions" D

< Add. Function Window appears >
i
3. Select number(s)/line(s) of desired Additional Function(s)
< Additional Function(s) (pictograph) appears in input section >

4. X model: press key "Enter"

XT model: as on X or press "Trigger function" touch key

< For identifying the stored Additional Function the pictograph is

displayed behind the cut size >
XT model

Subsequent Storing of Additional Functions

see also "Step Selection", page K5A-19.

1. Select program < Program-Data menu appears >

2. Select step number

3. X model: press key "Correction"
XT model: press touch keys "Input Mode On" + "Correction"

< Mode - display: CORRECTION >

4. Press key/touch-key "Additional Functions"

< Add. Function Window appears >

5. Select the number/line of the desired Additional Function

6. X model: press key "Enter"

XT model: as on X or press "Trigger function" touch key

< Additional Function is stored; pictograph is displayed behind the step position >
touch key "Trigger function"
Erase Additional Function: Repeat above procedure

K5C-2
5.0 Automatic Operation
List of Additional Functions

Additional functions (programmable to step) / pictograph: Operation:

Air supply complete air table ON

Air - table is switched on (when backgauge advances to a size with this
function)

Turning off the air:

a. automatic - with cut

b. manual - by pressing one cut button

Air supply complete air table OFF Shuts off automatic air-table during backgauge reverse

Air supply front table ON (with automatic mode only) Air supply to front table only.
After the cut, no backgauge advance is performed. A "timer" card (waiting time)
is displayed. Within this time period, the material can be discharged / put aside
on the front table. After the time has elapsed, the backgauge is advanced
automatically (timer cards 1-8) or must be started manually (timer card 9).

Only clamping, no knife!

Clamping without cutting

K5C-3
 5.0 Automatic Operation
Cont.: List of Additional Functions

Additional functions (programmable to step)/ pictograph: Operation:

Automatic cut release; Automatic knife prepared.

Automatic Knife ACTIV Start by pressing cut buttons!

Automatic Knife PREPARED Switches Automatic knife to "Automatic Knife Prepared" mode.

Examples:
Example 5: 100.000 Automatic Knife PREPARED
Example 1: 100.000 Automatic Knife PREPARED
LS 5.000 After each cut Automatic Knife
90.000 Automatic Knife ACTIV
is switched to "prepared".
80.000 Automatic Knife ACTIV
70.000 Automatic Knife is switched off
Example 6: 100.000 Automatic Knife PREPARED
60.000 Automatic Knife PREPARED
LS 5.000 Automatic Knife ACTIV
LQ *3 After 3 cuts Automatic Knife
Example 2: 100.000 Automatic Knife PREPARED
is switched to "prepared".
90.000 Automatic Knife ACTIV
80.000 Automatic Knife ACTIV
Example 7: 100.000 Automatic Knife PREPARED
70.000 Automatic Knife PREPARED
LS 5.000 Automatic Knife ACTIV
LQ *3 After 3 cuts Automatic Knife
Example 3
is switched off.
with Eltrotact: 100.000 Automatic Knife PREPARED
LS 5.000 Automatic Knife ACTIV
Example 8: 100.000 Automatic Knife PREPARED
LQ *1 Automatic Knife ACTIV
LS 5.000 Automatic Knife ACTIV
LS 2.000 Automatic Knife ACTIV
LQ *3 After 3 cuts Automatic Knife
LQ *1 Automatic Knife ACTIV
is switched to "prepared"
TC *5 After 5 cuts Automatic Knife is
TC *6 After 6 cuts Automatic Knife
switched off.
is switched off.

Example 4: 100.000 Automatic Knife PREPARED

LS 5.000 Automatic Knife ACTIV until front
limit stop is reached.

K5C-4
5.0 Automatic Operation
Cont.: List of Additional Functions

Additional functions (programmable to step)/ pictograph: Function:

To compensate for shifting of printed image on sheet.

Lay guide I
Set up:
Lay guide II For short cuts: Lay guide I
For long cuts: Lay guide II
Program example:
Compensation mode (expanded size display): lay guide 1 + 0,000;
1. Get to size with compensation I (F) on automatic mode.
Machine is ready to accept amount for compensation.
2. Use handwheel (fine adjustment) to adjust cut size to print or adjust with
Difference between actual and nominal size is stored as amount for
knob "Distorsion Correction"*.
compensation
3. Make cut

* A correction value adjusted by means of turning knob "distorsion

correction" must be moved to in any case. Otherwise, no correction value
can be transferred!
________________________________________________________________________________________________________________________________________

This function starts the process of Autotrim table as well as the function of
Autotrim Waste waste removal of cutting strips at the knife by blowing air device (if preadjusted;
see "Setting of Autotrim Parameter", page K5G - 4).
_______________________________________________________________________________________________________________________________________

Aligning of material against opened table flap.

Autotr. Align Material Backgauge advance will be started automatically/manually, resp. (see "Setting
of Autotrim Parameters") when time grade has been reached.
Note:
If function "Align: Ignore Light Barrier" (menu "Preset Functions") is selected,
automatic backgauge advance will only be activated if light barrier beams are
free of any obstacle.
_______________________________________________________________________________________________________________________________________

Function to push the cut labels forward by a short backgauge advance

AT. Label Pusher movement.
This function prevents the bottom labels from sticking to the cutting stick.

K5C-5
 5.0 Automatic Operation
Cont.: List of Additional Functions

Additional functions (programmable to step)/ pictograph: Function:

Ejector OFF Prior to backgauge reverse no automatic ejector

________________________________________________________________________________________________________________________________________

Backgauge advance "slow" Backgauge advances slow* (to size with this function)
* half the value of the selected advance speed step under "machine parame-
ters" (refer to page K5G - 1)
________________________________________________________________________________________________________________________________________

Jogging mark Knife block;

A stored jogging mark for exact line up against backgauge and side guides
will block the cut at that position. When pressing the cut buttons a beep sounds
and operation mode shows: JOGGING MARK
________________________________________________________________________________________________________________________________________

Step parameters The “step parameters” function allows the storage of parameters such as
duration of pre-clamping; clamping force etc. together with the individual nomi-
nal size (step) of the program selected.
The available parameters are listed in a “list of step parameters”. The individual
parameters can be selected and modified and also stored together with a step.
Please note!
The complete parameters contained in the list are stored together with the
step.

A step parameter function stored will be displayed in the program data image by
a green colored pictograph. The individual parameters are described in section
“Machine / step / program parameters”, page K5G-1.
Note:
The lists “machine parameters, program parameters and step parameters”
contain the same functions!

K5C-6
5.0 Automatic Operation
Cont.: List of Additional Functions

To store a nominal size with step parameters: X model D

1. Call a free program i

2. Enter a nominal size, such as 50 cm

3. Press key/touch key "Additional Functions"

4. Make selection "Step Parameters" XT model

5. Select key/touch-key "Machine-Parameters"

6. Adjust the individual parameters in the following way:

a. Select number/line of parameter
b. Select number of desired step

When all required parameters have been adjusted:

7. X model: press key "Enter"

XT model: as on X, or press "Trigger function" touch key

Selection "Copy list of parameters"

After this function has been selected the settings can be modified again.

The following functions can be selected:

1. Basic setting (reset parameters to factory setting)

2. Last setting (return to most recent setting stored)
3. Machine parameters (selection of machine parameters set)

K5C-7
5.0 Automatic Operation
Cont.: List of Additional Functions (Option)

Additional functions (programmable to step) / pictograph: Function:

This is an automatic function for aligning material or putting it aside.

Align material (pedal substitution function) For a preset waiting time after cutting the clamp remains on the cut material
(see machine parameters "Time to align or remove", page K5G - 4. In this
period, the material can be aligned on the front table –against the material
fastened by the clamp- or put aside.
As soon as this period has expired, the automated operation is continued.

Clamp unit at knife (special equipment, see Activate the holding-down clamp unit in front of the knife.
The cutting material is fixed in front of the table while cutting is performed.
below in this chapter) The clamping time is preset in the menu "Program parameters" via menu item
"holding-down clamp in front of knife" (page K5G - 4).

Activate holding-down device at backgauge

Clamp unit at backgauge active (special equipment, see
below in this chapter)
Deactivate holding-down device at backgauge
Clamp unit at backgauge passive (special equipment, see
below in this chapter)

Holding -down device, active Holding -down device, passive

K5C-8
5.0 Automatic Operation
Cont.: List of Additional Functions (Option)

Additional functions (programmable to step) / pictograph:

Swivel backgauge (special equipment, see

below in this chapter)

Tilting backgauge (special equipment, see

below in this chapter)

Fixomat (special equipment, see

below in this chapter)

Frontmark guide

Sidemark guide

Retractable sidegauge (special equipment, see

below in this chapter)

Sidegauge left, down

Sidegauge right, down

K5C-9
 5.0 Automatic Operation
EasyMode (XT)

EasyMode is a streamlined programming mode for setting up programs on XT

machines.
EasyMode allows to show all of the pictographs of the programmable additional
functions in the Data Menu program in order to ensure an efficient program E
generation. The numerical keypad is automatically shown on the display, so the
user can directly input the measurements. EasyMode reduces the program
generation time, because there is no longer any need to press function keys and
subsequently select the individual functions from the card index boxes.
Moreover, you can mask out any additional functions which are not being used.
External additional functions are only displayed if they have been saved under a
designation.
However, it is still possible to select additional functions via the function keys and
card index boxes.

EasyMode also includes the “Help” (X) touch key as a tool tip.
Once it has been selected, you can touch a pictograph and get the explanation of
the additional function in an information window above the pictograph. This
means, you can choose a function without even knowing the pictograph. E4
Activate the EasyMode

1. Press the “Input Mode On” touch key

2. Press the “EasyMode” (E) touch key

The EasyMode window is now shown with an input line and all of the picto-
graphs of the additional functions, arranged in the following way:
E1
Large window (yellow)
Upper part of the window (E1): additional functions, step parameters, external
additional functions
Center of the window (E2): program functions, program parameters,
E2
comments
Lower part of the window(E3): “Insert”, “Correct”, “Back to previous page of
menu” and “Help” (Tool Tip) E3
Small window, top right (E4, blue, docked to the large window)
Preselection of function keys “User-defined additional functions”, “Parameter list”
and “De-select additional functions” (red-colored touch key)
X

K5C-10
5.0 Automatic Operation
Continuation: EasyMode (XT)

EasyMode input line (E5)

All of the measurements, comments and pictographs of the additional functions
which have been input are first shown in an input line (E5) above the EasyMode
window. If necessary, the input may be edited. Only after pressing the “Enter”1) E5
key or the “Trigger function” touch key will the data be inserted into the program
data menu.

Selecting an additional function in EasyMode

In general, an additional function is selected by clicking on the pictograph/picto-
graphs. The selected additional functions are shown in a different color.
Please note: While the “Help” touch key is being activated no additional function
can be stored. The help function remains active, until it is turned off!

Storage procedures

Storing additional functions with the nominal size

1. Enter the nominal size via the numerical keypad1)

2. Click on the desired additional function(s) in the window*
3. Press the “Enter”1 key or “Trigger Function” touch key

Subsequent storage of additional functions with a nominal size

1. Select the first step number with the cursor

2. Press the “Correction” (2) touch key
3. Click on the pictograph(s) of the desired additional function(s)*
4. Press the “Enter”1) key or the “Trigger Function” touch key
1 2
Inserting additional functions with the nominal size

1. Select the step number where you wish to insert a new step
2. Press the “Insert” (1) touch key *Please note!
3. Click on the pictograph(s) of the desired additional function(s)* If the selected additional function does not constitute a logical feature for the
4. Press the “Enter”1) key or the “Trigger Function” touch key nominal size, the following message is output: Function not allowed (indicating
the error number)! Remedy: De-select the relevant function.

1)
on the inserted keypad or the control panel keyboard

K5C-11
 5.0 Automatic Operation
Continuation: EasyMode (XT)

Deselect additional functions in the EasyMode window*

In the little docking window, top right:

1. Press the red touch key (E6)

< All of the additional functions are activated (= shown in the same color) > E6
E7
2. Touch all of the pictographs you wish to remove (E7, color of pictographs
changes!)

3. Press the “Enter”1) key or the “Trigger Function” touch key

< The deselected pictographs are hidden >

If you wish to show all of the pictographs again:

1. Press the red touch key again

2. Press the “Enter”1) key or the “Trigger Function” touch key

< The deselected pictographs are shown again >

User-Defined Additional Functions

E8
In the little docking window, top right:

Press the “User-defined additional functions” pictograph (E8)

< All of the “user-defined additional functions” are shown. If there are several

menu pages, use the touch key “Cursor right/left” to scroll to the following
pages or go back to the previous ones>

Take over a block of user-defined additional functions

Same procedure as described in the ”Storage procedures” section. However,

1)
click onto the line of the “user-defined additional functions” block, rather than the on the inserted keypad or the control panel keyboard
individual additional function(s). This block will then be taken over into the Pro- * You can only deselect sheer additional functions (in the upper section of the
gram Data section. EasyMode window)!

K5C-12
5.0 Automatic Operation
Continuation: EasyMode (XT)

Parameter list (machine, step and program parameters)

In the little docking window, top right:

Press the “Parameter list” (E9) touch key

E9
(Default pictograph = Machine parameters (blue))

Depending on the selections made on the relevant parameter list (step param-
eters or program parameters in the EasyMode window) the pictograph will be
shown in the corresponding color.
After the selection, the parameters are shown and their values may be changed
by clicking on the corresponding step.
If there are activated machine parameters or program parameters for the current
program, the user can notice this from the corresponding pictograph being shown
in the header of the Program Data menu, with the following exception: As far as
step parameters are concerned the pictograph is saved in the program data
section after the stored program step.

If the menu consists of several pages, use the touch key “Cursor right/left”
to scroll to the following pages or go back to the previous ones.

Store parameters

1. Select the desired parameter page

2. Select the desired step of the parameter to be changed
3. Press the “Enter”1) key or the “Trigger Function” touch key

1)
on the inserted keypad or the control panel keyboard

K5C-13
 5.0 Automatic Operation
Display of "Optional Equipment" (option)

Operating panel (Special Function Module) "Optional Equipment":

Tilting backgauge

Swivel backgauge

Fixomat/Holding-down device

In the "Optional Equipment" function display of the program data display function-
al positions of special equipment of the machine - such as swivel backgauge,
tilting backgauge etc. are inserted.
Actual as well as nominal positions of the special equipment are represented
graphically and by indication of the adjusting value as a non-dimensional number.

Optional equipment - if available - is offered for selection on page 2... of the

special equipment selection under "file cards". Actual and nominal value, resp., or stored nominal position actual position
the actual functional position are displayed in panels after the respective file card
has been activated.
For adjusting the values or the functional position the corresponding keys on the
control panel (swivel backgauge, tilting backgauge, Fixomat/holding-down clamp)
or in the light-barrier housing (retractable side gauge) must be actuated.

When a nominal position with a stored optional equipment is approached a

section showing nominal and actual values as well as the functional positions is
inserted automatically into the Program Data menu.

The following types of optional equipment can be indicated:

Retractable side gauge

Fixomat
Swivel backgauge
Tilting backgauge
Clamp unit at backgauge

K5C-14
5.0 Automatic Operation
Swivel Backgauge (optional equipment)

With the POLAR Swivel Backgauge the print appearance on the sheet can be Operating panel (Special Function Module) "Optional Equipment":
aligned to the cutting line. The swivel range is shown in the "Optional Equipment"
section of the program - data - display in graphic form and by a digital number.

A stored Swivel Backgauge function (= angle correction) is displayed with a

pictograph behind the step position in the program data section.

Operation symbols:

Swivel backgauge
"0 - position"

symbol Angle compensation

Angle compensation
"Left-hand side" "Swivel Backgauge" "Right-hand side"

Swivel backgauge
"0 - position"
Angle compensation
"Right-hand side"
Angle compensation
"Left-hand side"

Storage of Swivel Backgauge Function with Angle Correction

1. Enter nominal position

2. Press touch-key "Additional Functions"

3. Select function "swivel backgauge"

< pictograph appears in input section >
4. Adjust via angle compensation keys or

5. Press key "Enter" or press "Trigger function" touch key

K5C-15
 5.0 Automatic Operation
Cont.: Swivel Backgauge (special equipment)

Subsequent Storage of a Swivel Backgauge Function

1. Select nominal position

2. Press touch keys "Input Mode On" + Correction"

3. Press touch-key "Additional Functions"

4. Select function "Swivel Backgauge"

< pictograph appears in input section >
5. Adjust angle compensation via keys or

6. Press key "Enter" or press "Trigger function" touch key

Attention:
If angle compensation is modified while the program is executed in auto-
matic operation, the new compensation value is automatically stored upon
release of cut instead of the value previously stored.

Deleting a Stored "Swivel Backgauge" Function with Angle

Correction

1. Select nominal position with swivel backgauge function

2. Press touch keys "Input Mode On" + Correction"

3. Press touch key "Additional Functions"

4. Select function "Swivel Backgauge"

< pictograph in input section is deleted >

5. Press key "Enter" or press "Trigger function" touch key

K5C-16
5.0 Automatic Operation
Tilting Backgauge (optional equipment)

The POLAR tilting backgauge allows a compensation of overcuts and undercuts - Operating panel (Special Function Module) "Optional Equipment":
predominantly on materials which are difficult to handle.
This is done by modifying the positioning angle with respect to the table surface.

If the machine is fitted with the function "Tilting backgauge" this is indicated by a
pictograph next to the nominal position in the program data section. "Overcut" position

Key assignment: Tilting Backgauge

"0 - position"
Tilting backgauge symbol
"0 - position" "Tilting Backgauge" "Undercut" position

"Overcut" position

"Undercut" position

Storing the "Tilting Backgauge" Function with Angle Correc-

tion

1. Enter nominal position

2. Press touch-key "Additional Functions"

3. Select function "Tilting Backgauge"

< pictograph appears in input section >
4. Adjust by means of angle compensation keys or

5. Press key "Enter" or press "Trigger function" touch key

K5C-17
5.0 Automatic Operation
Cont.: Additional Functions Tilting Backgauge

Subsequent Storage of a Tilting Backgauge Function with

Angle Correction

1. Select nominal position

2. Press touch keys "Input Mode On" + Correction"

3. Press touch-key "Additional Functions"

4. Select function "Tilting Backgauge"

< pictograph appears in input section >
5. Adjust angle compensation via keys or

6. Press key "Enter" or press "Trigger function" touch key

Attention:
If angle compensation is modified while the program is executed in auto-
matic operation, the new compensation value is automatically stored upon
release of cut instead of the value previously stored.

Deleting a Stored "Tilting Backgauge" Function with Angle

Correction

1. Select nominal position with tilting backgauge function

2. Press touch keys "Input Mode On" + Correction"

3. Press touch-key "Additional Functions"

4. Enter function "Tilting Backgauge"

< pictograph in input section is deleted >

5. Press key "Enter" or press "Trigger function" touch key

K5C-18
5.0 Automatic Operation
Fixomat (optional equipment)

Within the POLAR - Fixomat it will be possible to guide the printed sheets in the Attention!
same manner as done on a printing press. The Fixomat backgauge is equipped The function keys of the Fixomat are designed as double-function keys both,
with 2 front guides and 1 side guide. These guides can be selected individually, for Fixomat and holding-down clamp at the backgauge.
separately with the resp. keys. The position of front guides as well as side guide Superior half: Holding-down function
can be programmed. Any Fixomat function stored is represented by a pictograph Inferior half: Fixomat functions
next to the nominal position in the program data display.
Side- and frontmarks can be moved by hand over the whole width of the back-
gauge to any desired position.

Operation symbols:

Fixomat "0 - Position"

Frontmark Guide

symbol Frontmark Guide

Sidemark Guide
"Fixomat"
Fixomat "0 - Position"

Storage of a Fixomat Function

Sidemark Guide
1. Enter nominal position

2. Press touch-key "Additional Functions"

3. Select function "Fixomat"

4. Select Fixomat function by means of Fixomat keys on control panel

< pictograph appears in input section >

5. Press key "Enter" or press "Trigger function" touch key

K5C-19
 5.0 Automatic Operation
Cont.: Fixomat (optional equipment)

Subsequent Storage of a Fixomat Function Example Frontmark guide:

1. Select nominal position

2. Press touch-keys "Input Mode On" + Correction"

3. Press touch-key "Additional Functions"

4. Select function "Fixomat"

< pictograph appears in input section >

5. Press key "Enter" or press "Trigger function" touch key

Deleting a Stored Fixomat Function

1. Select nominal position with Fixomat function Example Sidemark guide:

2. Press touch-keys "Input Mode On" + Correction"

3. Press touch-key "Additional Functions"

4. Enter function "Fixomat"

< pictograph in input section is deleted >

5. Press key "Enter" or press "Trigger function" touch key

1. Align paper against front guides, make a cut

2. Turn pile around by 90°, align pile against left or right table side guides
and make the angle cut

K5C-20
5.0 Automatic Operation
Clamp unit at Backgauge (optional equipment)

The POLAR clamp unit at the backgauge allows even difficult materials to be Attention!
precisely positioned at the backgauge rake. In this way a higher cutting precision The function keys of the Fixomat are designed as double-function keys both for
is obtained. Clamp unit functions "passive" and "active" can be stored together Fixomat and clamp unit at the backgauge.
with the nominal position. Any clamping function stored is represented by a Superior half: clamp unit at the backgauge function
pictograph next to the nominal position in the program data display.
When a clamp unit function for a position less than 25 cm is stored, the clamp
unit will automatically return to "resting position" when approaching this position.
Upon - manual or automatic - backgauge return or change of program the clamp
unit moves automatically to its "passive position".

Storage of a Clamp Unit Function

clamp unit, active clamp unit, passive
1. Enter nominal position

2. Press touch-key "Additional Functions"

3. Select function "Clamp Unit" (passive/active)

< pictograph appears in input section >

5. Press key "Enter" or press "Trigger function" touch key

Subsequent Storage of a Clamp Unit Function

1. Select nominal position

symbol clamp unit "Active"
2. Press touch-keys "Input Mode On" + Correction" "Fixomat"
3. Press touch-key "Additional Functions"
clamp unit "Passive"
4. Select number/line of clamp unit function (passive/active)
< pictograph appears in input section >
clamp unit in "Resting
5. Press key "Enter" or press "Trigger function" touch key position"

K5C-21
 5.0 Automatic Operation
Cont.: Clamp Unit at Backgauge (optional equipment)

Deleting a Clamp Unit Function Stored

1. Select nominal position with clamp unit function

2. Press touch keys "Input Mode On" + Correction"

3. Press touch-key "Additional Functions"

4. Select function "Clamp Unit"

< Pictograph in input section is deleted >

5. Press key "Enter" or press "Trigger function" touch key

Adjusting the Pressure Force of the Clamp Unit

At the left-hand side of the handwheel of the manual precision adjustment a

pressure regulating valve is located which is used for adjusting the pressure force
of the clamp unit.

Adjust pressure force

(Adjust pressure force only with the clamp unit in "active position")

1. Pull controller handle downward (unlock)

2. Adjust pressure force by turning the controller (observe pressure gauge)
3. Push controller handle upward (lock)

K5C-22
5.0 Automatic Operation
TwinClamp (optional equipment)

The POLAR TwinClamp is used when there are substantial height differences TwinClamp
within one ream. Such variations are caused by varying inking, perforations or (resting position)
embossing (for example when dealing with bank notes). With increasing cutting
tolerances, the operator often has to cut with a reduced ream height which lowers
the cutting efficiency. The optional TwinClamp has been conceived for compen-
sating such height differences and increasing the ream height.

Benefit of TwinClamp:
- TwinClamp compensates height variations of materials in one and the same
ream.
- Increased ream height
- Improved cutting quality by more constant clamping
- No loss of quality when higher loads are processed
- Substantial reduction of manual intervention when cutting a ream
TwinClamp
The TwinClamp option includes the following parts: (active)

1. Hold-down clamp at the backgauge rake

The hold-down clamp at the backgauge rake is furnished with a special
rubber layer on the underside, which compensates different heights. In
order to allow the backgauge to move under the clamp when minor meas-
ures are processed, the hold-down clamp can be swiveled out by program-
ming (resting position). The clamping pressure of the hold-down clamp is
infinitely variable up to 6 bar (approx. 60 kg).

2. Special profile false clamp plate

The special profile false clamp plate is also provided with a 10-mm special
rubber layer on the underside. Therefore, it balances height variations and
improves the cutting quality by an even clamping process. Note: when a Pressure regu-
profile false clamp is used the opening is reduced to a max. 105 mm lating valve
(without profile false clamp plate: 130mm).

3. Wider pressure clamp

A wider pressure clamp helps to expand the area to be clamped and helps
to improve the cutting quality.
1
4. Extended backgauge rake
Because of the wider pressure clamp, the backgauge rake has been
extended by 50 mm. This allows to push the last label onto the front table.
However, the feed depth is decreased by these 50 mm.

K5C-23
 5.0 Automatic Operation
Cont.: TwinClamp (optional equipment)

The TwinClamp functions "passive" and "active" can be stored together with the Attention!
nominal position. Any TwinClamp function stored is represented by a pictograph The function keys of the Fixomat are designed as double-function keys both for
next to the nominal position in the program data display. Fixomat and TwinClamp at the backgauge.
When a TwinClamp function for a position less than 25 cm is stored, the Twin- Superior half: TwinClamp at the backgauge function
Clamp will automatically return to "resting position" when approaching this posi-
tion.
Upon - manual or automatic - backgauge return or change of program the Twin-
Clamp moves automatically to its "passive position".

Storage of a TwinClamp Function

1. Enter nominal position

2. Press touch-key "Additional Functions"

TwinClamp, active TwinClamp, passive
3. Select function "TwinClamp" (passive/active)
< pictograph appears in input section >

5. Press key "Enter" or press "Trigger function" touch key

Subsequent Storage of a TwinClamp Function

1. Select nominal position

2. Press touch-keys "Input Mode On" + Correction"

3. Press touch-key "Additional Functions"

symbol TwinClamp "Active"
4. Select number/line of TwinClamp function (passive/active) "Fixomat"
< pictograph appears in input section >
TwinClamp "Passive"
5. Press key "Enter" or press "Trigger function" touch key

TwinClamp in "Rest-
ing position"

K5C-24
5.0 Automatic Operation
Cont.: TwinClamp (optional equipment)

Deleting a TwinClamp Function Stored Pressure regulating valve

1. Select nominal position with TwinClamp function

2. Press touch keys "Input Mode On" + Correction"

3. Press touch-key "Additional Functions"

4. Select function "TwinClamp"

< Pictograph in input section is deleted >

5. Press key "Enter" or press "Trigger function" touch key

1

Adjusting the Pressure Force of the TwinClamp

At the left-hand side of the handwheel of the manual precision adjustment a

pressure regulating valve (1) is located which is used for adjusting the pressure
force of the TwinClamp.

Adjust pressure force

(Adjust pressure force only with the TwinClamp in "active position")

1. Pull controller handle downward (unlock)

2. Adjust pressure force by turning the controller (observe pressure gauge)
3. Push controller handle upward (lock)

K5C-25
 5.0 Automatic Operation
Clamp Unit at Knife (optional equipment)

The hold-down clamp unit in front of knife is a facility that fixes the cutting materi-
al in front of the knife while it is cut. In this way, any shifting or toppling over is position of clamp unit during
prevented. knife change procedure
A hold-down clamp function can be programmed together with a nominal position
or a label position (for parameter setting, i.e. timer modules, see page K5G-4)

Storage of a Clamp Unit at Knife Function

1. Enter nominal position

2. Press touch-key "Additional Functions"

3. Select function "Clamp Unit at Knife"

< pictograph appears in input section >

4. Press key "Enter" or press "Trigger function" touch key

Subsequent Storage of a Clamp Unit at Knife Function

1. Select nominal position

2. Press touch-keys "Input Mode On" + Correction"

3. Press touch-key "Additional Functions"

4. Select function "Clamp Unit at Knife"

< pictograph appears in input section > knife label material clamp unit
angle
5. Press key "Enter" or press "Trigger function" touch key

Please note!
During knife change, the hold-down clamp unit is simply tilted upward.

K5C-26
5.0 Automatc Operation
Retractable Side Gauge (optional equipment)

Hydraulically retractable side gauges make the rear table wider. This allows Operating elements in left light barrier housing :
sheets with a diagonal longer than the cut length to be turned in the machine.
Other advantages:

• Direct loading onto rear table of cutting machine is possible (e.g. Gripper
Transport System, Transomat 3BL or Turning Gripper).

Programmable additional functions under menu "Additional Functions"

• Side Gauge Left Down

• Side Gauge Both Down
1 3

Manual Operation
2
Selection of the manual functions:

Operation panel located in left light barrier housing!

1 Side gauge left down

2 Side gauge left and right down
3 Side gauge up (initial position)

K5C-27
 5.0 Automatc Operation
Stack Lifts, fixed with Semi-Automatic Height Control (optional equipment)

Attention! Light barrier housing left and right:

The area where the lift is operating, and an additional
zone of approx. 50 cm in any direction must be marked in
black and yellow as a safety area. 4 5 4 5

POLAR stack lifts ensure that the material can always be taken from pallets or
stacked on pallets at the operator’s normal working height. The lifts are con-
nected to the hydraulic system of the cutting machine.

POLAR stack lifts are supplied with a semi-automatic height adjustment system.
Once a ream of cutting material has been taken off the stack, the lift is automati-
cally adjusted so that the upper edge of the pile is precisely at the working height
at the touch of a key.
When the lift is being loaded, it can always be lowered via pushbutton. In this
way, the upper edges of the pile are again adjusted to the operator’s working
height.
Preselector switch:
The desired working height is preadjusted at the lift by means of a light barrier. on the cover of the side table, r-h or l-h side

Controls:

with the lift on the right-hand side: on the keypad of the right light-barrier
housing
key 4 "Elevating the lift", key 5 "Lower-
ing the lift" 6

with the lift on the left-hand side: on the keypad of the left light-barrier
housing
key 4 "Elevating the lift", key 5 "Lower-
ing the lift"

The preselector switch for setting the modes "Standard lift function" (0), "Un-
loading the lift" (I) / Loading the lift (II)" is on the cover of the side table, on the
right or left.

"Lift unloading" mode:

1. Turn preselector switch (6) to " I " position

Unloading the lift Standard lift function Loading the lift

K5C-28
5.0 Automatc Operation
Stack Lifts, fixed with Semi-Automatic Height Control (optional equipment)

2. Press key 4 "Elevating the lift" Light barrier housing left and right:

< The lift is elevated until it contacts the light barrier >

"Lift loading" mode: 4 5 4 5

1. Turn preselector switch (6) to "II" position

2. Press key 5 "Lowering the lift"

< The lift is lowered until it contacts the light barrier >

Attention!
For safety reasons, near the bottom (approx. 17 cm above the ground) the
machine can only be lowered in the inching mode.

"Standard lift function" mode:

1. Turn preselector switch (6) to "0" position

2. Press key 4 "Elevating the lift" or key 5 "Lowering the lift" (inching mode!)
6

Unloading the lift Standard lift function Loading the lift

K5C-29
K5C-30
5.0 Automatic Operation
Menu Key: Program Functions

Key/Touch-key "Program Functions" X model D

Program functions are no additional functions, but special step types in which a
i
value or size can be programmed.

The key/touch-key "Program Functions" comprises the following functions**.

78X/XT 92X/XT 115X/XT 137X/XT 155X/XT 176X/XT

Nominal Position x x x x x x
Programmable Ejector x x x x x x XT model
Eltrotact x x x x x x
ET-Block with Absolute Pos. x x x x x x
Program Loop x x x x x x
Comments* x x x x x x
Program parameters x² x² x² x² x² x²

x Function available;
x² only on XT-machines

∗ Various frequently used comments are also listed on page 2 of the "Program
Functions" menu (press key/touch-key twice). This allows to quickly enter the
comments into the cutting programs without any need to use the menu
structure of the "Comments" menu.

** Technical alterations reserved

K5D -1
 5.0 Automatic Operation
Program Functions: Nominal Position

Selection of step type

For instance, if an Eltrotact function has been selected for programming during
program generation (input request of label size is indicated in input section), but
you rather want to store a normal cut size/comment etc. the step type (input
mode) can be changed very fast.

Program Functions: Comments

Instead of cut sizes text informations (comments) can be stored.
e.g.: • Clamp pressure
• Hints regarding information in program-information-display
Guide hints
• Turning of stock, etc.

Note: A maximum of 20 letters/numbers can be entered into one line!

Procedure:

1. X model: press key "Program Functions"

XT model: press touch keys "Input Mode On" + "Program Functions"

< Program Data menu shows "Program Functions Window" >

2. Select "Comments"
< Comments selection window is shown >

K5D -2
5.0 Automatic Operation
Continuation Program Functions: Comments

Three possible variations! *Please note!

On the 78X - 176X models, the alphabetic input is carried out via a soft-
A. Selection of comment key function on the display. The keypad is first shown in minimized form,
B. Input of comments in the top right-hand corner of the display. To maximize the keypad:
C. Functional comments (only available with "Data Control") Press the „Multiplication“ key!
Select a symbol using the cursor. Transfer it to the input section by
pressing the key „Cursor-Home“ (see also page K5A - 24).
A. User defined comments

The screen displays all comments previously stored under "Preset Functions, sub-
menu "User Defined Comments". The comments can be transfered directly from the
window into the program.

Procedure: A. User defined comments

Conditions:Input section is cleared

1. Select "User defined comments"

< Comment selection window is shown >

2. Select number/line of desired comment

< the alphabetic keypad is superimposed* Maximize the alphabetic keypad!
The comment is displayed in the input section>

if actual comment has to be changed:

3. X model: press key , enter new comment and press key "Enter"
XT model: Press key "Delete" on the alpha keypad, enter new com-
ment and press "Enter" on the alpha keypad.

Procedure: B. Input of comments

1. Select "Input of comments"

2. Enter comment via alpha keypad*

4. X models: press key "Enter"

XT model: press key "Enter" on the alpha keypad (!)

K5D -3
 5.0 Automatic Operation
Continuation Program Functions: Comments

Procedure: C. Functional Comments

This list contains comments that start / introduce certain interactive functions
once they have been transferred into the cutting program.

Functional Comments (e. g.): "Get new material"

To accept the comment:

• Enter number of comment.

Every time, the program cycle reaches this functional remark, the system calcu-
lates the number of layers/reams already processed in the current job. The
values are summed up every time the functional remark is reached.
The function „progress control“ in menu „Auxiliary program functions“ or in menu
„Program information“ is used for entering the initial values for the functional
comment. After the first run (counting) has been performed, a pop-up window
opens in the data menu. Here, you have to enter the number of sheets and save
it by pressing the "Enter" key.

Subsequent Storing of a Comment into an Existing Program

1. Select step
2. X model: press key "Insert"

XT model: press touch keys "Input Mode On" + "Insert" *Please note!
On the 78X - 176X models, the alphabetic input is carried out via a soft-
3. Press key/touch-key "Program Functions" key function on the display. The keypad is first shown in minimized form,
in the top right-hand corner of the display. To maximize the keypad:
4. Select "Comments" Press the „Multiplication“ key!
Select a symbol using the cursor. Transfer it to the input section by
5. Select "User Defined Comments" or "Input Of Comment" *
pressing the key „Cursor-Home“ (see also page K5A - 24).
6. Enter comment via alpha keypad or select comment number

7. X model: press key "Enter"

XT model: as on X, or press "Enter" on the alpha keypad or "Trigger

function" touch key

K5D -4
5.0 Automatic Operation
Program Functions: Programmable Ejector

Prior to each backgauge return movement the backgauge advances to the cutting
line (automatical ejector). This makes turning of cutting material easier.

This ejector is set to approx. 20 cm.

If the ejector has to be extended or reduced, an ejector size has to be stored or
inserted.

Example:

1. Call desired program

2. Mark the step number where you want to store the ejector value.

3. Press key/touch-key "Insert" < step is left open for entry >

4. Press key/touch-key "Program Functions"

5. Select "Progr. Ejector"

6. Enter ejector size with numerical keypad

7. X model: press key "Enter"

XT model: as on X or press "Trigger function" touch key

K5D -5
 5.0 Automatic Operation
Program Functions: Program Loop

Automatic (multiple) repetition of a program part

Example:

1. Call up an allocated program

The program part with step numbers 3 and 4 shall be repeated three times, for
instance.

2. Select step number 2

3. Press key/touch-key "Insert" < step line is left open for entry >

4. Press key/touch-key "Program Functions"

5. Select "Program Loop"

6. Press key (limitation margin) and confirm with key "Enter" or

"Trigger function" touch key

7. Select step no. 5

8. Press key/touch-key "Insert" < step line is left open for entry > Please note !
If the function "PL block – branch table" in the directory "Preset
9. Press key/touch-key "Program Functions" functions" has been set to "YES", the input of a comment will be offered
after the delimiter number or the number of repetitions has been input
(allocation of PL block names!)
10. Select "Program Loop"

11. Press key (repetition factor) and confirm with key "Enter" or

"Trigger function" touch key

Program run:

The program part between the loop limits (PL) will be repeated three times.
Processed number of loops are shown in the size display during automatic mode.

K5D -6
5.0 Automatic Operation
Program Functions: Repeat Cut Device ELTROTACT

Fast and easy programming of a sequence of equal cut sizes Example:

Definition of terms used for the ELTROTACT:

Label size* Size of label or trim cut

Label quantity** Number of consecutive cuts of same size

Total cuts** Sum of all cuts of repeat sequence

* The following additional functions can be programmed together with the "Label
Size":
Clamping Without Cutting, Air Table On, Air Front Table On, Backgauge Advance
Slow, Holding Down Clamp in Front of the Knife, Autotrim-Functions.

** The following additional functions can be programmed together with a "Label

Quantity" (LQ) or "Total Cuts" (TC):
Autotrim-Functions, Automatic Knife active/prepared, Automatic Ejector OFF, Air
ON/OFF, Air Front Table ON and External Additional Functions.
The function will be performed when the program number of cuts is reached.

Symbols on display:

Behind step number LS = Label Size

LQ
TC
= Label Quantity
= Total Cuts
} Repeat block The number of the total cuts performed is indicated next to the size

Repeat block examples:

LS LS LS
TC LQ LQ
TC LS
LQ
etc.
TC

K5D -7
 5.0 Automatic Operation
Program Examples with ELTROTACT

Size DIN A3 (untrimmed 31 x 43 cm ) to be cut into several strips. 4

Input: 5

1. Select free program 6 4 x 5,5 cm

7
2.
8
3. 9
10
11
4. 12 10 x 2 cm
13
5. 14
15
6. Select key/touch-key "Program Functions" 16
17
2
7. Select "ET Label size"
1 3
8. Enter "Label size" * (e.g.):

9. Enter "Label quantity" (e.g.):

10. Enter "Label size" (e.g.):

11. Enter "Label quantity" (e.g.):

12. Select "Total cuts": (Program Functions)

13. Enter number of "Total cuts":

* Attention !
After the first label size has been input, there will be an automatic request to
enter the number of labels in the input section, i. e. without previous selection of
the ET Label Quantity function. After that, again automatically, the operator is
asked to enter the next label size, etc. Once the last label quantity has been
entered, you only have to select the "Program Functions" key / touch key to enter
the total number of cuts.

K5D -8
5.0 Automatic Operation
Determination of Remaining Measurement with ELTROTACT

Remaining measurement = remaining measurement after entering of initial Example:

measurement and repeat block
Initial measurement 1 70,000
Determination of remaining measurement (see example on the right): 2 LS 5,000
25 cm
3 LQ 5
26 cm
1. Select total number of cuts (TC) with cursor Repeat block 4 LS 1,000
1 cm
5 LQ 1
2. Actuate button or press "Trigger function" touch key
6 TC 6

Remaining measurement appears in display 70 - 26 = 44,000 cm = remaining measurement

Repeat Block - Automatic Repetition

Automatic (also multiple) repetition of a repeat block

Example:
Example: The repeat block (example on the right) should automatically be
repeated twice in succession
Initial measurement 1 70,000
Key input: 2 PL 1 loop limit
3 LS 5,000
1. Select step number "2 LS 5.000" 4 LQ 5
2. Press key "Insert" resp. touch-key "Input Mode On" + "Insert" 5 LS 1,000
6 LQ 1
3. Press key/touch-key "Program Functions": Select "Program Loop" 7 TC 6
8 PL 2 repeat factor
4. Press key (limitation margin) and confirm with key "Enter" or with 9 42,000
"Trigger function" touch key 10 35,000
5. Select step number "8 42.000" with cursor

6. Press key/touch-key "Insert" Descriptions of functions:

7. Press key/touch-key "Program Functions": Select "Program Loop" The repeat block between loop limit and repeat factor will be repeated twice in
8. Press key (repeat factor) and confirm with key "Enter" or with succession.

"Trigger function" touch key

K5D -9
 5.0 Automatic Operation
Program Functions: ET-Block with Absolute Positions

This function serves to convert the programs generated in the Eltrotact mode into
absolute positions. When a program is converted into absolute positions, the cut
sizes can be corrected much easier. The cut sizes are also available for a distor-
tion correction that might become necessary.
Note: This function can also be selected in the step selection mode!

Procedure

1. Call up a program with Eltrotact sequence

2. X model: press key "Program Functions"

XT model: press touch keys "Input Mode On" + "Program Functions"

3. Select "ET Block with Abs. Pos."

4. Enter the step numbers of the Eltrotact sequence from first label size to
total number of cuts

5. X model: press key "Enter"

XT model: as on X, or press the "Trigger function" touch key

< Eltrotact sequence is converted into absolute positions >

K5D -10
5.0 Automatic Operation
Program Functions: Program Parameters (XT)

The “Program Parameters” function allows the adjustment and storage of

functions, such as duration of pre-clamping; clamping force etc. to the program.
The available parameters are listed in a “list of program parameters”. The indivi-
dual parameters can be selected, modified and also stored together with the
program.
Please note!
All parameters contained in the list are stored as a whole together with the
current program.

A program parameter function will be displayed in the program data menu by a

purple colored pictograph. The individual parameters are described in section
“Machine / Step / Program Parameters”, page K5 -1.
Note:
The lists “machine parameters, program parameters and step parameters”
contain the same functions!

To store a program parameter to the program:

1. Call a program

2. Press touch keys "Input Mode On" + “Program Functions”

3. Make selection “Program Parameters”

4. Press touch-key "Machine Parameters"

< the color of the list of program parameters changes >

5. Adjust the individual parameters in the following way:

a. Select the number/line of the parameter < Card is activated >
b. Select number/line of the desired step < Card is deactivated >

You can change several parameters in a row!

Abandon the menu "Program Parameters":

Press touch-key "Program-Data"

K5D -11
 5.0 Automatic Operation
Continuation Program Functions: Program Parameters (XT)

Selection "Copy list of parameters"

After this function has been selected the settings can be modified, if required.

The following functions can be selected:

1. Basic setting (reset parameters to factory setting)

2. Last setting (return to most recent setting stored)
3. Machine parameters (selection of machine parameters set)

K5D -12
5.0 Automatic Operation
Menu Key: External Additional Functions (XT)

Key/Touch-key "External Additional Functions"

Key/Touch-key "External Additonal Functions" includes the following functions*:

78X/XT 92X/XT 115X/XT 137X/XT 155X/XT 176X/XT

4 positions programmable
with backgauge start x² x² x² x² x² x²

4 positions programmable
with backgauge stop* x² x² x² x² x² x²

x² only on XT-machines

* Technical alterations reserved

K5E-1
 5.0 Automatic Operation
External Additional Functions

This key enables the programming of up to 8 external devices (relays), connected

to the machine. These devices can be peripheral or directly mounted on machine.
When activating "External Additional Functions" the window "External Additio-
nal functions" is displayed. The window indicates all the External Additional
Functions previously stored under "Preset Functions", sub-menu "External
Additional Functions" (see page K5B-32).
Storing of an External Additional Function to a step number is done in the same
way as the storage of an additional function.
Positions 1 - 4 are activated upon the start of the backgauge; positions 5 - 8
active upon backgauge stop.

Storing of External Additional Functions with Ente-

ring of Cut Size

1. Enter cut size

2. Press touch-key "External Additional Functions"

3. Enter number/line of External Additional Function

< pictograph appears in input field >

4. Press key "Enter or press the "Trigger function" touch key

"Trigger function" touch key
< Pictograph of External Add. Function will be stored after cut size.
When backgauge travels to a program stop (in automatic mode) with
External Add. Function the respective function will be activated >

K5E-2
5.0 Automatic Operation
Subsequent Storing / Erasing of External Additional Functions
1. Call program

2. Select step

3. Ppress touch keys "Input Mode On" + "Correction"

4. Press touch-key "External Additional Functions"

5. Press line of External Additional Function

6. Press key "Enter" or press the "Trigger function" touch key

K5E-3
 5.0 Automatic Operation
External Additional Functions: Optional Equipment "Gripper Loading System G" (Autotrans MM)

The POLAR “Gripper Loading System G” is an optional equipment for cutting Menu "External Additional Functions"
machines, which is meant for the automatic transfer of formats (maximum size
80 x 120 cm) from peripheral units located directly at the rear table of the cutting
machine (such as the pressing station) onto this rear table of the cutting machine.
Undivided cutting material can be transported by POLAR “Gripper Loading
System G” in program controlled cycles. To this end, the gripper function can be
added when generating the cutting program.
GRIPPER START 1
The gripper functions are stored via menu touch-key "External additional
functions". GRIPPER START 2

The following external additional functions have been adjusted in the

factory:

4 .....
5 GRIPPER START 1
6 .....
7 .....
8 GRIPPER START 2

Switching the gripper loading system on

Addition control panel at the cutting machine. The location of the
1. The gripper system is connected when the cutting machine is switched on. operational controls depends on the machine equipment!
2. Switch driving voltage on at the control panel Gripper

Manual operation of gripper loading system G 1

The manual operation is carried out via an additional control panel at the cutting 2
machine. The panel has the following operational controls:
3
1 Emergency-stop button
2 Driving voltage On
3 Driving voltage Off 4
4 Gripper Start 1
5 Gripper Start 2
5

K5E-4
5.0 Automatic Operation
External Additional Functions: Optional Equipment "Gripper Loading System GF" (Autotrans M)
Addition control panel at the cutting machine. The location of the
Variations operational controls depends on the machine equipment!

The gripper loading system is available in two control versions, i.e.:

A. without intermediate stop = Transport of cutting stock from the

peripheral device directly onto the rear
table of the cutter

B. with intermediate stop = 1.Transport of cutting stock from the

peripheral device to an intermediate stop
position
2. From intermediate stop position onto
the rear table of the cutter

Depending on the peripheral equipment 1 or 2 control panels are provided

for the gripper control (Control panel A with 1 start button, Control panel B Gripper positions 1 Initial position
with 2 start buttons) 2 Intermediate stop
3 Position cutter table

1 2 3

Control panel A Control panel B Control panel B

(near peripheral (on the cutter, (on the cutter,
Peripheral
equipment) w ithout w ith intermediate
equipment
intermediate stop)
stop)

Jo g g er X X X

Air - board lift X X X

Peripheral Intermediate Cutter table
device table
Transomat X X X

K5E-5
 5.0 Automatic Operation

External Additional Functions: Optional Equipment "Gripper Loading System GF" (Autotrans M)

Technical data Control panel A

Gripper speed 20 cm/s Start 1 Emergency OFF

Compressed air 5 - 7 bar
Power required 0,3 kW
Height of layer max. 16,5 cm
min. 2 cm

Max. stock size depending on the machine type 115 - 176

Control panels

Control panel A
(mounted next to the periph. device)

with version "without interm. stop":

The start button moves the grippers from the inital position to the cutter table and
back to the initial position Control panel B

with version "with interm. stop": Emergency OFF

Grippers only moves to intermediate stop position
Driving voltage on

Control panel B Driving voltage off

(on the cutter, without interm. stop with 1 start button, function as on control
panel A)
Start 1
Start 1
moves grippers from initial position to intermediate stop

Start 2
moves grippers from intermediate stop to the cutter table and back to initial Start 2
position

K5E-6
5.0 Automatic Operation
External Additional Functions: Optional Equipment "Gripper Loading System GF" (Autotrans M)

Operation / Function Control panel A

Switching machine "ON" Start 1 Emergency OFF

1. Turn main switch of cutter from the "0" position to "I".

2. Switch driving voltage on at control panel B

Turning machine "OFF"

Wait until automatic operations have ended, then

Turn main switch of cutter from position "I" back to "0"

Activating the gripper function

Conditions: 1. Function of the peripheral device must be terminated

2. Retractable side gauge at cutter table is moved down (to be
programmed on the cutter)
3. Backgauge in rear end position Control panel B

Functions:
Emergency OFF
with version "with intermediate stop":
Driving voltage on
1. Actuate "Start 1" at control panel A or "Start 1" at control panel B

< Grippers pull cutting stock from the periphal device to the intermediate Driving voltage off
stop >
Start 1
2. Actuate "Start 2" on control panel B

< Grippers pull cutting stock onto the rear table of the cutter; retractable side
gauge moves up; if the cutter is in automatic mode: backgauge moves to the
first cut position; grippers return to their initial position >
Start 2

K5E-7
 5.0 Automatic Operation
External Additional Functions: Optional Equipment "Gripper Loading System GF" (Autotrans M)

with version "without intermediate stop":

• Actuate Start button at control panel A or B

< Grippers pull cuting stock from the peripheral device onto the rear table of
the cutter.
if the cutter is in automatic mode: backgauge moves to the first cut position;
grippers return to their initial position >
GRIPPER START 1
On versions with intermediate stop the cutting stock is moved to the inter-
mediate stop when this button is pressed. GRIPPER START 2
A transport of the material up onto the rear table of the cutter is only possi-
ble bye pressing start button 2 at control panel B.

Automat

When the external additional functions 5 and 8 are applied, the automatic
function of the gripper will be started. The gripper transports the material out
of the peripheral unit and onto the cutter rear table. External function 5 (Gripper Start 1) programmable to step number

External function 8 (Gripper Start 2) programmable to step number

Emergency OFF
Upon actuation of the emergency OFF button all functions are stopped
immediately.

To continue the operation:

• Pull the cutting stock manually out of the grippers

• Unlock the emergency OFF button
• Actuate one of the start buttons:
< Grippers return to their initial position >

K5E-8
5.0 Automatic Operation
External Additional Functions: Optional Equipment "Gripper Loading System GF" (Autotrans M)

Safety area / Secondary operation

The area around the machine must be equipped with a guard rail.
Only authorised persons (determined internally by company) may remain in this key-operated switch
area.

It is forbidden for anyone to remain in the safety area

during operation

If there is a malfunction which cannot be eliminated even after resetting the

machine, secondary operation can be activated.
In doing this, the gripper transport system is put into a safety position.

Caution!
Caution! Before activating the secondary operation, one must ensure
Only authorised persons may carry out activation that the gripper transport system cannot collide with the
of secondary operation peripheral equipment or parts of the cutter.

Possible function using secondary operation: Cutting Activating the secondary operation

1. Switch off the cutter!

2. Enter safety area

3. At switch box of gripper system:

Put key into key-operated switch and turn the switch

4. Leave the safety area

5. Switch on the cutter again

K5E-9
 5.0 Automatic Operation
External Additional Functions: Optional Equipment "Turning Gripper" (Autoturn)

The POLAR turning gripper is an optional equipment for big cutting machines to
enable large-sized material to be turned automatically on the tear table of the
cutting machine.
Turning grippers enhance the continuous output of the high-speed cutter, especial-
ly when dealing with heavy materials. Retractable side gauges on both sides of the
high-speed cutter permit the turning of sizes up to 105 x 145 cm (POLAR 155, START FEEDER
table of 2 meters) and 122 x 164 (POLAR 176). SEPARATING CUT
START TURNING
The POLAR turning gripper lets you turn and align the undivided cutting material in LAY GUIDE RIGHT
a program controlled cycle. For this purpose, the turning gripper functions can be CHANGE LAY GUIDE
integrated into the cutting program. TURN 90 DEGREES
CHANGE FEEDER
UNLOADING/TURN 180 DEG
The turning gripper functions are stored via menu key/touch-key “External additi-

onal functions” .

The following external additional functions have been defined in the factory:

(1) START FEEDER

(2) SEPARATING CUT
(3) START TURNING
(4) LAY GUIDE, RIGHT
(5) CHANGE LAY GUIDE
(6) TURN 90 DEGREES
(7) CHANGE FEEDER
(8) UNLOADING/TURN 180 DEG

Possible combinations:

Please note: Left lay guide has been preadjusted!

Programming of combinations (example):

3+6 = Turn 90 degrees, left lay guide

3+7 = Turn 180 degrees, left lay guide

K5E-10
5.0 Automatic Operation
External Additional Functions: Optional Equipment" Turning Gripper" (Autoturn)

Description of sequence of functions for “Turn 90°” Illustration of the sequence of functions for “Turn 90°, left lay guide”

1 Home position: Turning gripper above the left-hand retractable side gauge
(A)

2 Both retractable side gauges (left and right) move downward. 1. - 3. 4. 5. - 6. 7.

3 Grippers of turning gripper (B) move down and are opened

4 Paper lifters (C) lift the cutting material

5 Grippers move into cutting material

6 Grippers are closed

7 Paper lifters return to home position A B C

8 turning gripper moves the cutting material away from the left-hand side 8. 9. 10. - 11. 12. - 15.
gauge (depends on individual program)
90°
9 Cutting material is turned 90°

10 The left retractable side gauge moves up

11 The turning gripper pushes the material to the left side gauge

12 The right retractable side gauge moves up

13 Grippers open, leave the cutting material, close and move upward

14 Backguage of cutting machine moves to next cutting position

15 turning gripper returns to home position (retractable side gauge, left side)

K5E-11
K5E-12
5.0 Automatic Operation
Menu Key: Auxiliary Functions

Key/touch key "Auxiliary Functions"

X model

The key/touch key "Auxiliary functions" includes the following functions*: D

78X/XT 92X/XT 115X/XT 137X/XT 155X/XT 176X/XT

i
Cut and record x x x x x x
Difference of positions x² x² x² x² x² x²
Set/Delete program protection x x x x x x
Simulation without cuts x² x² x² x² x² x²
Correction of cut position x x x x x x
Warning Skip Cutting x x x x x x
CountMonitor (Progress control) x x x x x x
PL-block branch table x² x² x² x² x² x²
Correction of position x² x² x² x² x² x²
_______________________________________________________________________________ XT model
CountMonitor • • • • • •
_______________________________________________________________________________

x function available
x² only on XT-machines
• optional equipment

Note:
The functions "Simulation without cuts", "Correction of cut position",
"Warning: skip cutting" and "PL-block branch table" can only be activated
in automatic mode of operation (selection numbers of functions are only
visible in automatic mode).

* Technical alterations reserved

K5F-1
 5.0 Automatic Operation
Auxiliary Functions: Set/Delete Program Protection

Protection of program against modiffications and deletion. *

1. Call program

2. X model: press key "Auxiliary Functions"

XT model: press touch keys "Input Mode On" + "Auxiliary Functions"

3. Select "Program Protection"

< Asterisk (*) sign appears behind program number. Both, the program in-
formation display and the program survey display automatically provide
those programs fitted with program protection with an asterisk or the resp.
pictograph >

Delete protection: - repeat above procedure

Auxiliary Functions: Simulation without Cuts (XT)

Only possible in automatic operation!
By entering a cut number it is possible to jump to a deliberate cut size of a
program - either with or without Eltrotact.

1. Set cursor to start size

2. Switch automatic operation on!

3. Press touch-key "Auxiliary Functions"

4. Select "Simulation without cuts"

5. Enter desired cut number (from start size) e.g.
< cursor marks step number; cut size appears in input section >

6. Move backgauge to step (positioning)

* see also Program Directory (page K5A-34/35)

K5F-2
5.0 Automatic Operation
Auxiliary Functions: Cut and Record
1. Select free program

2. Press key/touch-key "Auxiliary Functions"

3. Select "Program When Cutting"

4. Make cut < actual size is stored upon every cut >

Switching the function off:

• After program set-up, switch the function off by selecting the function again
or
• Press key "Automatic Operation ON"

Auxiliary Functions: Difference of Positions (XT)

If any variations of the size caused by stretching or shrinking are detected on a
printed sheet they can be determined by the "difference of posit." function when
the program is started. Constant label sizes of a cutting sequence can be calcula-
ted faster and their differences due to distorsion can be determined and compen-
sated.

Example:
1. Move backgauge manually to first cut size according to printed image

2. Press touch-keys "Input Mode On" + "Auxiliary Functions"

3. Select "Difference of Posit."

4. Move backgauge manually over the printed image to be measured
< difference is indicated in input section >

5. Divide the difference by the number of labels

< label size including distorsion has been calculated >

The label size can be transferred directly to the Eltrotact block. If other
differences must be determined:
Clear the input section and repeat the procedure.

K5F-3
 5.0 Automatic Operation
Auxiliary Functions: Correction of Cut Position

Only possible in automatic operation!

1. Switch Automatic Operation on.

2. Move backgauge to nominal position

3. X model: press key "Auxiliary Functions"

XT model: press touch-key "Input Mode On" + "Auxiliary Functions"

4. Selection "Correction Of Cut Position"

5. Check nominal position by means of optical or mechanical cutting-line indicator

6. Correct position by means of handwheel or with knob "Distortion Correction"*

* Positioning of distortion!

7. Select "Save YES/NO"

8. Press the "Enter" key or the "Trigger function" touch key or release a cut
< modified position is stored >
.......

Auxiliary Functions: Skip Cutting Warning On

Only possible in automatic operation!

Switching the warning in the Program Data menu on or off.

Example
If the backgauge has been moved to a certain position in automatic operation,
but still no cut has been released, and the operator tries to go to the next cut
size by pressing the key "backgauge advance movement", the warning "Skip
cutting?" will be issued.

If the cut is to be skipped: Press key twice

K5F-4
5.0 Automatic Operation
Auxiliary Functions: CountMonitor (Progress Control)

The "Progress Control" function provides the possibility to count processed

sheets.
Once the function has been selected, a pop-up window in the Program Data Menu
shows the values summed up that have been activated in the program via the
functional comment "insert layer/ream".
By selecting the corresponding number, the following default values can be entered
or the indicated values can be modified:
Please note: The same values can be entered into the "Program Information" menu!

• Height (# of sheets)
• Waste (# of sheets)
• Sheet counter

Enter correction values:

1. Enter selection number/line
2. Enter the value via numerical keyboard and store by pressing key "Enter"

The window can be removed from the display by pressing key or

Auxiliary Functions: PL-Block Branch Table (XT)

Condition: • Presetting under "Preset functions" (PL-block
branch table YES/NO)
• Automatic operation ON

The processing of combination runs (combination sheets) is made much easier

by processing blocks of strips. -Strip blocks which had been stored by the pro-
gram can quickly be found and allocated by a certain PL block name. To do this,
define a program loop function (PL) and a comment (= block name) in the cutting
program. After the automatic function has been switched on, menu button "Auxili-
lary functions" and function "PL-block branch table" have been selected, the
program data display opens up a window which indicates all the block names
defined in a program, and the corresponding step numbers. You can highlight
and select a PL-block. The cursor of the Program Data menu will then jump to
the corresponding block name in the program.

K5F-5
 5.0 Automatic Operation
Auxiliary Functions: Contin. PL-Block Branch Table (XT)

Storage procedure (see example in the fig. on the right):

1. Enter comment (= block name)

2. Enter the cut size.
3 Enter the cut size.
4 Enter the cut size.
5. Define the program loop (highlight the corresponding PL block)
6 Enter comment (= block name) (comment mode is automatically
activated!)
7 Enter the cut size.
8 Enter the cut size.
9 Define the program loop (highlight the corresponding PL-block)
10 Enter comment (= block name) (comment mode is automatically
activated!)

Display and selection of a PL-block in the cutting program

Condition: • Presetting under "Preset functions" (PL-block branch

table: YES)
• Automatic operation ON

1. Call up a program
2. Press touch-key "Automatic ON" !
3. Press touch-key "Input Mode On" + "Auxiliary functions"
4. Select item "PL-block – branch table"
< "block name" window is displayed". All defined PL-blocks of the current
program with names and step numbers are listed here >
5. Select the desired PL-block in the window
6. Select a PL-block via touch key " = " in the block name window!
< The cursor in the Program Data menu jumps to the corresponding
PL-block. The backgauge is moved to this position >.

Note:
If no comment is entered, the stored program loop appears without name in the
PL-block branch table!
If one or several PL-blocks are deleted in a program, or if any PL-block names
are modified, the step numbers or the PL-block names in the PL-block branch
table are automatically updated.

K5F-6
5.0 Automatic Operation
Auxiliary Functions: Correction of Position (XT)

The menu "Correction of Position" allows to make a basic correction of the

position due to the material processed.
A correction value can be selected from the list "Main Menu", item "Correction
For Material"*. The correction value can be modified also at this time by pressing
the "+" or "-" touch key on the index card.

When a correction of position has been selected it is shown on the index card
"correction of position" indicating its designation and material number (see
Fig. "A").

* Note
The correction values are only included in the list if they have been previously A
stored in menu "Preset Functions", item "Set-Up Machine", item "Correction For
Material".

K5F-7
 5.0 Automatic Operation
CountMonitor (Optional on X and XT)

The CountMonitor is a modified kind of progress control (see page K5F - 5).

The CountMonitor serves to determine the number of sheets or the feeding

height of the material being cut. This is done by the modified functional com-
ment "Get new material" which must be added to the program (see page K5D -
4).
As soon as the program cycle has reached this programmed functional comment,
the relevant feature will be activated and the "CountMonitor" pop-up window for
selecting a counting function be shown. Once a counting function has been
selected and the preset values have been input, the determined values will be
added every time the cycle overruns the functional comment.
The relevant values are determined by the pressure clamp. An operator prompt
on the display asks the operator to take the required initialization steps and
guides him/her.

The following functions are available in the CountMonitor:

1 CountMonitor disabled
2 Count const. material height
3 Measure height & count sheets
4 Measure height & sum up cm

CountMonitor disabled

Disable the CountMonitor function. As soon as the functional comment is rea-

ched, there will be no function!

Count const. material height

For counting reams of a constant height. Make the following inputs:

1. Enter ream height (number of sheets) ?

Take over the value of the previous input
or
enter a new value via the numerical keypad (overwrite previous value)

K5F-8
5.0 Automatic Operation
Continuation: CountMonitor (Optional on X and XT)

2. Press the "Trigger Function" touch key

3. Enter "Quantity to be produced (no. of sheets)"?

Take over the value of the previous input
or
enter a new value via the numerical keypad (overwrite previous value)

4. Press the "Trigger Function" touch key

Measure height & count sheets

The function allows to count the sheets of the material being processed.

Every time the machine is turned on and after the program is called up for the
first time with the stored functional comment "Get new material" the following
initialization process is required:

1. Clear the table!

Lower the pressure clamp onto the empty machine table by means of the
pedal. Press the cut buttons and keep them pressed, until the display asks
you to release the cut buttons and the pedal. Please note! The knife does
not move!

2. Place a counted number of sheets from the cutting material (= reference

sheets) beneath the clamp.

3. Press the pedal to lower the pressure clamp onto the material. Press the
cut buttons and keep them pressed, until the display asks you to release
the cut buttons and the pedal. Please note! The knife does not move!

Input of values:

4. Enter the number of sheets in the batch

Take over the value of the previous input
or
enter a new value via the numerical keypad (overwrite previous value)

5. Press the "Trigger Function" touch key

K5F-9
 5.0 Automatic Operation
Continuation: CountMonitor (Optional on X and XT)

6. Enter the quantity to be produced (no. of sheets)

Take over the value of the previous input
or
enter a new value via the numerical keypad (overwrite previous value)

7. Press the "Trigger Function" touch key

Measure height & sum up cm

For measuring and summing up the feeding height of the material being pro-
cessed.

1. Enter the quantity to be produced (pile height in mm)

Take over the value of the previous input
or
enter a new value via the numerical keypad (overwrite previous value)

2. Press the "Trigger Function" touch key

Indication of determined values

On all of the above described functions of the CountMonitor the Program Data
menu will automatically open a window which displays the accumulated values as
soon as the preset values have been reached .

While the CountMonitor function is active the window can also be activated
manually via the "CountMonitor" auxiliary function from the card index box, in
order to control the current values.
The window can be hidden by pressing the key .

K5F-10
5.0 Automatic Operation
Menu Key: Machine Parameters (Program-/Step Parameter)

Key/Touch-key (see also "Programm-Parameters" K5D-11 and "Step- All of the displays depend on the resp. machine equipment!
Parameters K5C-6)

The key/touch-key "Machine Parameters" includes the following functions to be preset*: X model

78X/XT 92X/XT 115X/XT 137X/XT 155X/XT 176X/XT D

Pressing time before cut x x x x x x
Pressing time no cut
Clamping forces table
x
-
x
•²
x
•²
x
•²
x
x
x
x
i
Pressure force sensors - - •² •² •² •²
Pressing force level - •² •² •² x x
Backgauge acceleration x² x² x² x² x² x²
Backgauge deceleration x² x² x² x² x² x²
Backgauge speed x² x² x² x² x² x²
Backgauge smooth stop x² x² x² x² x² x²
Optimization of clamp x x x x x x
Clamp up when knife = BDC x² x² x² x² x² x²
Clamp light barrier - - •² •² •² •²
Smooth prepressure - - •² •² •² •² XT model
Highspeed cutting - - •² •² •² •²
Autotrim blowing air - - •² •² •² •² example, menu page 1
Start/Stop Autotrim
blowing air - - •² •² •² •²
Time to align or remove x² x² x² x² x² x²
Clamp unit at knife** - - •² •² •² •²

- function not available

x function available • special equipment
x² only on XT - machines •² special equipment, only on XT-machines

* Depending on machine equipment. Technical alterations reserved

** only on Autotrim-machines

Machine Parameters
The menu "Machine Parameters" allows to preset various basic adjustments for the
program cycles. These adjustments are valid for all programs stored in the machine,
unless these have been fitted with "Program Parameters" or "Step Parameters".
The function "Machine Parameters" is marked in the program data menu by a blue
colored pictograph in the measurement display and in the program heading. The menu
can be paged through using the cursor keys or pressing the menu key/touch-key twice.

Selection / Modification of a parameter

1. Select number/line of parameter
2. Select desired step
3. Exit menue by pressing key or key/touch-key "Program Data".

K5G -1
 5.0 Automatic Operation
Functions of the "Machine Parameters" (Program/Step Parameter) menu

Pressing Time Before Cut example, menu page 1:

This function is used for setting the clamping time of the clamp. The cut is retar-
ded after that.

Pressing Time No Cut

(only for nominal positions with programmed additional function "Clamping
without cut") With this function the clamping time of the clamp is adjusted for
function "Clamping without cut".

Option "Automatic clamp pressure adjustment"

Pressure force level

On machines fitted with automatic clamping pressure regulation and on machine
type 176 the clamping force can be preselected in various stages.
The adjusted clamping stage is indicated as a pictograph in the measurement

section (and/or with clamping force sensors ON) with the clamping stage
number superimposed.

Pressure Force Sensors

Machines fitted with automatic clamping pressure regulation are provided with
sensors in the cutting machine table which controlling the clamping pressure
corresponding to the respective size. The function of the sensors can be activa-
ted and deactivated with this option.

Info standard values

Indication of clamping pressure of the respective grades of clamping force.
The current clamping pressure is highlighted.

Backgauge Acceleration
Adjustment of feed acceleration of the backgauge

Backgauge Deceleration
Adjustment of backgauge braking for forward movement of backgauge

Backgauge Speed
Adjustment of backgauge speed during forward movement

K5G -2
5.0 Automatic Operation
Functions of the "Machine Parameters" (Program-/Step Parameter) Menu

Backgauge Smooth Stop example, menu page 1:

Selection: Yes/No!
After selection of this function the backgauge is stopped very smooth for posi-
tioning.

Optimization of clamp
During elevation the clamp stops above the cutting material after a preselected
time has expired (steps 1 - 9).
Parameters: 1 backgauge starts when clamp is in upper end position
2 backgauge starts when knife is in upper end position
3 - 9 backgauge starts when clamp is in corresponding position
above the material

Options with "Optimization of Cutting"

Clamp Light Barrier

Selection Yes/No
Detection of upper edge of cutting material by light barrier. The upward move-
ment of the clamp is stopped as soon as the light barrier detects the upper edge
of the cutting material.

Highspeed Cutting
Backgauge advance movement is carried out already during the knife upstroke

Smooth Prepressure (pedal substitution)

Selection: Yes/No
Smooth positioning of clamp on cutting material.

Options with "Autotrim"

Autotrim Blowing Air

Selection: Yes/No!
Switching Autotrim blowing air on or off, resp.

Start/Stop Autotrim Air

Adjustment of time for switching Autotrim blowing air on.
Position "6" corresponds to the lower dead centre of the knife (knife on cutting
stick)
Positions 1 - 6 = knife in downward movement
Positions 7 - 9 = knife in upward movement

K5G -3
 5.0 Automatic Operation
Functions of the "Machine Parameters" (Program-/Step Parameter) menu

Clamp up when Knife = BDC

Selection: Yes / No
The clamp is moved upward as soon as the knife upstroke is started, i.e. it has
left the Bottom Dead Center of the knife. This allows the material to be advanced
more rapidly (saving time).

Time to align or remove

Presetting of timer modules for additional functions “Align Material”, “Autotrim
Align Material” and "Front Table Air Supply".

Settings:
• Timer modules 1 – 8
Once the time has expired, the backgauge advance movement is automatical-
ly started (Condition: light barrier is not interrupted! See also section “Preset
functions”, function “Align: Ignore Light Barrier YES/NO")

• Timer module 9
backgauge advance movement must be started manually

Clamp unit in front of knife

Presetting of timer modules for switching the hold-down clamp in front of the knife
unit on or off ahead of BDC or after BDC of knife. (BDC = Bottom Dead Center).

Selection "Copy list of parameters":

After this function has been selected the settings can be modified again. The
following functions can be deleted:

1. Basic setting (reset parameters to factory setting)

2. Last setting (return to most recent setting stored)

K5G -4
5.0 Automatic Operation
Menu Key: User Defined Additional Functions (Additional Function Blocks, XT)

Touch-Key "User Defined Additional Functions"

Menu for collecting frequently repeated combinations of several additional functions

(blocks of additional functions).

In this menu, a maximum of 27 user-defined additional functions blocks can be

collected and permanently stored on three menu pages. In one step, these additional-
functions blocks can be added to a cut size by simple selection. The blocks of
additional functions are stored on the index card under a certain name. In this way
the operator can store various blocks of step types on different pages of the menu, for
instance, as step type “nominal position” on page 1, step type “Eltrotact” on page 2
etc..

78X/XT 92X/XT 115X/XT 137X/XT 155X/XT 176X/XT

User defined additional functions x² x² x² x² x² x²

x² only on XT - machines

K5H - 1
 5.0 Automatic Operation
User Defined Additional Functions

How to transfer a block of additional functions into the menu "User-defined Menu "User Defined Additional Functions"
additional functions" when a nominal position with additional functions is
entered

1. Enter nominal position

2. Press touch key "Additional Functions"

3. Select the additional functions requested (assemble a block)

4. Press the "User-defined additional functions" touch key

Select the desired page with the cursor touch keys (A).

5. Press the touch key "Into card index box"

6. Select the index card where the additional functions block is to be stored
A
<the alphabetic keypad is superimposed >

7. Enter and store a designation

< The "Program Data" menu is indicated. After the touch key „user-defined
additional functions“ has been selected again, the block of additional
functions is stored on the previously selected index card“ >

How to transfer a stored block of additional functions from the menu to a

cut size

1. Enter the cut size

2. Press the "User-defined additional functions" touch key
Select the corresponding page with the cursor touch keys (A).

3. Select the requested index card.

4. Press the "Trigger function" touch key

< The additional-functions block is stored with the cut size >

K5H - 2
5.0 Automatic Operation
User Defined Additional Functions

Subsequent storing of an user defined additional function

1. Select step number with cursor

2. Press the touch keys "Input Mode On" + "Correction"

3. Press the "User-defined additional functions" touch key

Select the desired page with the cursor touch keys.

4. Select the requested index card

< The "Program Data" menu is indicated >

5. Press the "Trigger function" touch key

< user defined additional function block is stored behind nominal

position >

Deleting of an user defined additional functions

Condition:
Input section is clear. No additional functions in the input section!
The deletion is carried out by an overwrite procedure with a blank line!

1. Press the "User-defined additional functions" touch key

Select the desired page with the cursor touch keys.

2. Press the touch key "Into card index box"

3. Select index card to be deleted

< user defined additional function block is deleted >

K5H - 3
K5H - 4
5.0 Automatic Operation
Autotrim 80 (option)

Autotrim 80 = max. width of waste: 80 mm*

Cuttings from outside trim and intermediate cuts can be automatically disposed of
by means of POLAR AUTOTRIM 80.

The front table of the Autotrim 80 cutter can be opened and the cuttings are
dropped into a bin or the customer’s waste removal system.
When the table is opened a flap moves up which serves as a gauge for the labels
already cut and prevents the waste from being pushed onto the front table.

Frictional electricity makes some waste paper stick to the knife. Autotrim 80 is
fitted with a device for removing such cuttings. Autotrim 80 is fitted with an
integrated blowing facility to remove the cutting strips from the knife.

The wide opening of the table has the labels transported so far onto the front
table that their removal - to the right or left side - can also be done automatically
by a pusher.

To collect products or labels which have already been cut, you can place a
support plate on the front table. Then lower the table by the size of the support
(max. 4 mm) by pressing the key. These (lowering and lifting) functions are
programmable, too!
During the cutting process, the support plate is automatically fixed on the front
table by partial vacuum. The unit can be changed over automatically from blown
air to suction air.

During any opening / closing process of the Autotrim front table the light barrier
of the machine ensures a safe operation! Whenever the light barrier is obstructed
while the front table is opened or closed, the function will be stopped immediately.

* depending on material to be cut

K5K - 1
 5.0 Automatic Operation
Autotrim 80 (option)

Controls for Manual Operation of Autotrim Table Manual functions:

(Control panel in the right-hand light-barrier housing)

1 open table

2 close table

3 lower table

4 lift table (home position) 3 4

1 2

Controls for Programming the Autotrim Functions

5 Programmable additional function

integrated in the "Additional functions" touch key

K5K - 2
5.0 Automatic Operation
Autotrim 80 (Option): Basic Adjustment of Front Table

The surface of the front table (10) must be approx. 0.2 mm lower than the rear
table surface (11).
11 10
0,2 mm
Unless this is the case, make the following adjustments:

1. Aerate lowering cylinder (12)

2. Deaerate lifting cylinder (13)
3. Loosen counternut (14) at fork head
4. Turn threaded bolt (15) until front table is at proper level
5. Tighten counternut

Adjustment of lowering level of front table

The material or labels that have been cut can be collected on a support plate* on
the front table. To level the height of this plate the Autotrim front table can be
lowered by the thickness of this support plate by pressing key „lower table“ (max.
4 mm).
These functions (lowering and lifting) can be programmed!
During the cutting process the support plate is firmly held to the front table by a
vacuum. Changeover from blowing to suction air is done automatically.
When thinner support plates are used the lowering level of the front table can be
corrected in the following way:

Beneath the Autotrim front table:

1. Deaerate lifting cylinder (13)

2. Deaerate lowering cylinder (12)
3. Loosen counternut (16)
4. Turn adjusting nut (17) until table is at proper lowering level
5. Tighten counternut

* recommended support plate: epoxy glass reinforced laminate 0.5 - 1 mm strong

14 15 13 12 17 16

K5K - 3
 5.0 Automatic Operation
Autotrim 80 (Option): Manual Operation

Autotrim 80 = max. width of waste: 80 mm*

* depending on material to be cut

Manual Operation
Example:

1. Align ream at backgauge and move to position of outside trim or inter-

mediate cut 1 2

2. Press key (1)

<Front table is opened; flap moves upward>

3. Trigger the cut

Once the clamp has returned to upper final position the front table is closed
automatically.

Safety Facilities
Machine light barrier!

If the light barrier is interrupted while the front table is opened or closed the
machine function will be stopped immediately.

Once the light barrier has been enabled again:

1. Open the table by pressing key (1)

2. Close the table by pressing key (2)

K5K - 4
5.0 Automatic Operation
Autotrim 80 (Option): Automatic Operation

Programming the Autotrim Function While Genera-

ting the Cutting Program
The Autotrim additional functions can be programmed together with any cut
size where cuttings or waste paper is produced.. This is done by means of
menu key/touch-key "Additional Functions".
When performing repeat steps with ELTROTACT the "Autotrim"-function can
be programmed together with the trim cut sizes.

Available functions in Autotrim Menu:

• Autotrim waste
• Autotr. Align Material
• Raise Autotrim table
• Lower Autotrim table

Autotrim waste
This function starts the process of Autotrim table as well as the function of
waste removal of cutting strips at the knife by blowing air device (if preadju-
sted; see "Setting of Autotrim Parameters", page K5K-6).

Autotr. Align Material

Aligning of material against opened table flap.
Backgauge advance will be started automatically/manually, resp.(see „Setting
of Autotrim Parameters“) when time grade has been reached.
Note:
If function "Align: Ignore Light Barrier" (menu "Preset Functions") is
selected, automatic backgauge advance will only be activated if light barrier
beams are free of any obstacle.

Raise Autotrim table

Lifting of Autotrim front table

Lower Autotrim table

Lowering of Autotrim front table for the collection of labels on a support plate.
Here, the unit is automatically switched over from blown air to suction air.

K5K - 5
 5.0 Automatic Operation
Autotrim 80 (Option): Automatic Operation

Setting of Autotrim Parameters

Setting of Autotrim parameters will be done with touch-key "Machine Parame-
ters".

Autotrim Blowing Air

Selection: Yes/No!
Switch Autotrim blowing air on or off

Start/Stop Autotrim Air

Adjustment of time to switch Autotrim blowing air on or off.
Position "6" corresponds to the lower dead centre of the knife (knife on cutting
stick)
Positions 1 - 6 = knife is moving downward
Positions 7 - 9 = knife is moving upward

Time to Align or Remove

Preadjustment of the time grade for Additional Function "Autotr. Align Material"

Settings:
• Time grade 1 - 8
Automatic backgauge advance when time grade is reached.

• Time grade 9
Manual backgauge advance by operator

Clamp unit in front of knife

Presetting of timer modules for switching the hold-down clamp in front of the knife
unit on or off ahead of BDC or after BDC of knife. (BDC = Bottom Dead Center).

AT clamp blowing air on

Presetting the start time for the supply of blown air at the hold-down clamp in
front of the knife.

K5K - 6
6.0 Knife Change

The knife may only be changed by personnel especially instructed

for this purpose!
Always use the knife change facility when changing or transporting
the knife outside the knife case!

Please make sure to verify the effectiveness of the safety

installations before every shift and after every knife change.
It is recommended to record the test results!

K6 - 1
 6.0 Knife change
Knife Change "OptiKnife" on Types 115, 137, 155, 176

Removal of knife Required tools: 1 T-wrench (for knife screws)

1 knife change facility
1. Select display "Main Menu" 2 knife handles
Select "Knife Change / Correction"* 1 adjusting wrench (for knife lift, adjusting screws, eccentric
Select "(1) Knife Change / Adjust knife position"* bolt and fixing screws)

19

2. Open flap for knife change (19).

With adjusting wrench: Loosen fixing screws (a and y).

Observe menu display!

3. With adjusting wrench: turn supporting cams (b) and eccentric bolt (c)
counter clockwise up to the stop. Tighten fixing screw of eccentric bolt (y) b
again!
Confirm "Eccentric bolt positioned to minimum"*.

* on X machines: Enter the number via numerical keypad

on XT machines: Actuate the line on the display

K6 - 2
6.0 Knife change
Knife Change "OptiKnife" on Types 115, 137, 155, 176

19

4. In display: select cutting material*

4 4

5. Close flap for knife change (19) and actuate foot pedal
< clamp stops approx. 2 cm above the table >

6. Press cut buttons (4)

< knife bar moves to lower final position and remains there >.
Remove the two knife screws at the very left-hand side.
* on X machines: Enter the number via numerical keypad
on XT machines: Actuate the line on the display

K6 - 3
 6.0 Knife change
Knife Change "OptiKnife" on Types 115, 137, 155, 176

26.4

7. Press cut buttons < knife moves into upper position >.
Open flap for knife change.

8. Remove remaining knife screws

9. Place knife change facility (26.1) in front of knife marks (26.2)

26.2 26.1
10. Insert T-wrench (26.3) into allen screw (26.4) and lower the knife until the
knife edgel matches with the window pins (26.5) on the knife change
facility.
26.3
11. Screw the knife handles (26.6) into holes of knife tightening the knife
change facility.

12. Turn T-wrench further, until suspending bolts (26.7) in knife holes become
free. Lift knife with knife change facility out of machine.

13. Store and secure knife in knife case!

14. Loosen knife handles and remove knife change facility. 26.7
15. Move the clamp upward by actuating the pedal several times.
Turn or replace cutting stick (see page K6 - 21).
Move the clamp downward by actuating the pedal again
26.6

26.1 26.5

K6 - 4
6.0 Knife change
Knife Change "OptiKnife" on Types 115, 137, 155, 176

Inserting of knife z
Attention!
Clean the knife if necessary! ( .Caution! Bare cutting edge. Risk of
injury!)
On types 115 - 176: In case of worn knifes (appr. 130 mm) screw distance
pieces (z) onto the knife back!

1. Place knife change facility onto knife in knife case.

Screw knife handles into new knife.
Take knife out of knife case and place it on a flat surface.

2. Loosen knife handles (26.6) in such a way that the knife change facility
gets moveable

3. Move knife change facility until knife edge matches with the window pins
(26.5) at knife change facility.
Tighten knife handles.

4. Use knife change facility to place knife upright on table and slide to the
knife bar.

5. Adjust knife suspending device of knife lift (26.10) by means of T-wrench

in such a way that it can be pushed onto suspension lugs.
Place knife on lugs.
26.6
6. Wind the knife up a little with knife lift .
Remove knife handles and knife change facility.

Wind knife all the way up .

Warning!

When winding the knife up into the knife carrier do not use excessive force!
If you experience any difficulty or resistance please inspect the condition of
the knife before proceeding! 26.5
Bowed knives can irrevocably damage the knife lifting mechanism.
Use another knife.
Have the damaged inspected and repaired by your knife grinder.

K6 - 5
 6.0 Knife change
Knife Change "OptiKnife" on Types 115, 137, 155, 176

7. Screw knife screws slightly into inferior line of knife fastening drillings
Attention!
In case of worn knife (knife height approx. 130 mm) use
superior line of fastening drillings.
19
Tighten the knife screws (d).

8. Close flap for knife change (19) and press cut buttons. b
< knife bar moves to lower final position >
Screw-in slightly the two remaining knife screws on left-hand side

9. Push paper strips under the knife on left-hand and right-hand side.
a
Loosen the both knife screws (d).

10. Lower the knife onto the cutting stick by means of the knife lift (knife must
be placed parallel onto the cutting stick! Paper strips must be clamped!).

11. With adjusting wrench: Turn supporting cams (b) clockwise up to the stop.
Tighten safety screws (a)!
Tighten all the knife screws from centre towards both ends alternately by
means of T-wrench.
12. Press cut buttons < knife bar moves to upper final position >
Tighten both screws on the right-hand side.

13. Make check cut: press cut buttons

< knife bar moves to lower final position >

K6 - 6
6.0 Knife change
Knife Change "OptiKnife" on Types 115, 137, 155, 176

Have the paper strips been cut through? If so:

Press cut buttons < knife bar moves to upper final position >

Menu: select "Finish knife change"* 19

< Program Data menu appears >

If the paper strips have not been cut through:

14. By means of adjusting wrench:

Loosen fixing device of eccentric bolt (y).
Turn eccentric bolt (c) clockwise.
Tighten fixing screw of eccentric bolt (y)!

15. Make a check cut: press cut buttons

Have the paper strips been cut through now? If so:

16. In display: select "Finish knife change"*

< Program-Data menu appears > y

Attention!
Subsequent to every knife change, check breaking pin. If necessary, tighten it.
c

* on X machines: Enter the number via numerical keypad

on XT machines: Actuate the line on the display

K6 - 7
 6.0 Knife change
Knife Change with Con-Rod Adjustment (Option, on Types 115, 137, 155 only)

Required tools (from toolbox):

1 T-wrench (for knife screws/knife lift)

1 knife change facility
2 knife handles
1 adjusting gauge
2 fork wrenchs (for con-rod adjustment)

Removal of knife

1. Select display "Main Menu"

Select "Knife Change / Correction"
Select "Knife Change/Adjust knife position"

Observe menu display!

2. In display: select cutting material*

* on X-machine: enter number via numerical keyboard

on XT-machine: touch line in the display

K6 - 8
6.0 Knife change
Knife Change with Con-Rod Adjustment (Option, on Types 115, 137, 155 only)

3. Actuate pedal (11) < clamp stops approx. 2 cm above the table >

4 11 4
4. Press cut buttons < knife bar moves to lower final position >
Remove both left-hand knife screws.

5. Press cut buttons < knife bar moves to upper final position >

K6 - 9
 6.0 Knife change
Knife Change with Con-Rod Adjustment (Option, on Types 115, 137, 155 only)

6. Open flap at front panel for knife change. Remove remaining knife screws 26.4
7. Place knife change facility (26.1) in front of the knife with their slots
matching the marks
19
8. Insert T-wrench (26.3) into allen screw (26.4) and lower the knife, until
knife edge matches with the window pins (26.5) at knife change facility.

9. Screw the knife handles (26.6) into holes of knife tightening the knife
change facility.

10. Turn T-wrench further, until suspending bolts of knife lift (26.7) in knife
holes become free.
Slide knife on supports out of machine.

11. Store and secure knife in knife case!

26.2 26.1
Loosen knife handles and remove knife change facility.

12. Move the clamp upward by actuating the pedal several times.
Turn or replace cutting stick (see page K6 - 21). 26.3
Move the clamp downward by actuating the pedal again.

Inserting of knife

1. Attention!
Clean knife if necessary!

Caution! Bare cutting edge! Danger of injuries! 26.7

Use adjusting gauge (26.8) to determine height of knife in knife case.

will be continued on next page! 26.6

26.1 26.5

K6 - 10
6.0 Knife change
Knife Change with Con-Rod Adjustment (Option, on Types 115, 137, 155 only)

Attention!
In case height is less than 130 mm the spring stop (26.9) of the 26.8
adjusting gauge must be positioned against the upper edge of the
knife.
In case height of knife to be inserted is less than 130 mm, screw the
rails (x) included in the delivery onto the knife bar from the rear.
In case height of knife is more than 130 mm remove rails if in use.

26.9

X
2. Close flap for knife change.
Press cut buttons < knife bar moves to lower final position >

3. Place the adjusting gauge (26.8) in front of the knife bar in such a way that
the adjusting pin (27) points towards hole (28) in knife bar. (If they do not
line up, re-adjust knife bar, see page K6-14).

27
28

4. Press cut buttons < knife bar moves to upper final position >
26.8
5. Open flap for knife change

K6 - 11
 6.0 Knife change
Knife Change with Con-Rod Adjustment (Option, on Types 115, 137, 155 only)

6. Position knife change facility onto new knife in knife case.

Screw in both knife handles.
Lift knife out of knife case and place it on a flat surface.

7. Loosen knife handles (26.6) in such a way that the knife change facility
gets moveable. Move knife change facility until knife edge matches with
the window pins (26.5) at knife change facility. Tighten knife handles.

8. Place knife with knife change facility upright on table and slide it to the
knife bar. Adjust knife suspending device of knife lift (26.10) by means of
T-wrench in such a way that it can be pushed onto suspension lugs.
Place knife on lugs.

9. Wind the knife up a little with knife lift .

Remove knife handles and knife change facility.

Wind knife all the way up .

26.6

Warning!
When winding the knife up into the knife carrier do not use excessive force!
If you experience any difficulty or resistance please inspect the condition of
the knife before proceeding!
Bowed knives can irrevocably damage the knife lifting mechanism.
Use another knife.
Have the damaged inspected and repaired by your knife grinder.
26.5
10. Tighten knife screws slightly; then tighten screws from centre towards both
ends alternately by means of T-wrench

K6 - 12
6.0 Knife change
Knife Change with Con-Rod Adjustment (Option, on Types 115, 137, 155 only)

11. Close flap for knife change.

Press cut buttons < knife bar moves to lower final position >

12. Insert and tighten the two remaining screws at the left-hand side

13. Press cut buttons < knife bar moves to upper final position >

14. On menu display: Select "Finish knife change"*

< Program-Data menu appears >

15. Make check cut with paper sheet

if the sheet has not been cut through:

Adjust knife bar (see page K6-14)

Attention! Subsequent to every knife change, check breaking pin. * on X-machine: enter number via numerical keyboard
If necessary, tighten it. on XT-machine: touch line in the display

K6 - 13
 6.0 Knife change
Knife Change with Con-Rod Adjustment (Option, on Types 115, 137, 155 only)

Adjustment of knife bar on types fitted with con-rod adjustment

1. Place paper strips onto cutting stick on left-hand side and right -hand side

2. Open flap for knife change

29
Observe menu display!

3. In display: select cutting material to be cut *

29.1
4. Close flap for knife change
29.2
5. Actuate foot pedal < clamp moves down to lower position >

6. Press cut buttons < knife bar moves to lower final position >

7. Remove access hole lid from front panel

8. Loosen locking nut (29.1) on con-rod.

Turn the turn buckle (29); use it for adjusting the knife to the required
height.

9. At rear of machine: 29.4

Loosen locking nut at eccentric lever (29.4).
Align knife parallel to cutting stick by means of eccentric lever.
Tighten locking nut at eccentric lever and at con-rod.

10. Insert access hole lid

11. Press cut buttons < knife bar moves to upper final position >

12. On menu display: Select "Finish knife change" *

< program-data display appears >

13. Make check cut with paper sheet

Attention! Subsequent to every knife change, check

breaking pin. If necessary, tighten it.
* on X-machine: enter number via numerical keyboard
on XT-machine: touch line in the display

K6 - 14
6.0 Knife change
Knife Change "OptiKnife" on Types 78 and 92

Removal of knife Required tools: 1 T-wrench (for knife screws)

1 knife change facility
1. Select display "Main menu" 2 knife handles
Make selection "Knife Change/Correction"* 1 adjusting wrench (for knife lift, adjusting screws, eccentric
Select "Knife Change/Adjust knife position"* bolt and fixing screws)

19

2. Open flap (19) for knife change.

With adjusting wrench: Loosen safety screws (a and y).

Observe menu display!

3. With adjusting wrench: turn supporting cams (b) and eccentric bolt (c) b y c
counter clockwise up to the stop.
Tighten safety screw (y) again!

Confirm "Eccentric bolt positioned to minimum"*

* on X-machine: enter number via numerical keyboard

on XT-machine: touch line in the display

K6 - 15
 6.0 Knife change
Knife Change "OptiKnife" on Types 78 and 92

4. On the display: Select type of material*

5. Close the knife change flap and actuate the pedal.

< The clamp moves downward and stops approximately 2 cm above the
table>

6. Press the cut buttons and keep them pressed

< The knife bar moves to the lower final position and remains there >
Remove the two exterior left-hand knife screws. * on X-machine: enter number via numerical keyboard
on XT-machine: touch line in the display

K6 - 16
6.0 Knife change
Knife Change "OptiKnife" on Types 78 and 92

7. Press the cut buttons: < The knife bar moves to the upper final position >.
Open the knife change flap

8. Remove the remaining knife screws

9. Place the adjusting wrench into the allen screw (X) of the knife lift. Lower
the knife by turning the adjusting wrench clockwise
(with a new knife: position the knife about 1 cm above the cutting stick)

Caution! Bare cutting edge. Risk of injury!

10. Introduce the knife handles (D) into the long holes in the knife change
facility (A) and fasten the knife change facility lightly at the marked drillings B D
in the knife (knife change facility must remain movable). Take the knife
change facility at the upper edge (B) and pull it upward, until the dead stop
(C) contacts the knife bevel. (When you look through the opening in the
knife change facility, the tip of the cutting edge should be flush with the
lower edge of the opening). Firmly screw the knife handles into the knife.

11. Lift the knife with the knife change facility out of the machine.

12. Put the knife with its knife change facility into the knife case. A
First, remove the locking screws in the knife case (by pushing them
down).
Remove the knife handles and the knife change facility
Insert the locking screws into the knife case and fasten the knife.

13. Move the clamp upward by actuating the pedal several times.
Turn or replace the cutting stick (see page K6-21). C
Lower the clamp by means of the pedal.

K6 - 17
 6.0 Knife change
Knife Change "OptiKnife" on Types 78 and 92

Inserting the knife

1. When handling a new knife in the knife case: Remove the locking
screws in the knife case (by pushing them down). Clean the knife
from oil and dirt.

Be very careful when handling the knife-edge. Risk of injury!

2. Fix the knife change facility to the new knife (see the marks) in the knife
case by using the knife handles.
Please note ! Before tightening the knife handles:
Take the knife change facility at the upper edge (B) and shift it in the
long holes, until the dead stop (C) contacts the knife bevel.

¡Caution when dealing with old knife cases!

When dealing with older cases, the knife change facility cannot be
directly screwed onto the knife in the case. First lift the knife out with
B
the knife handles and place it on an even support plate.

3. Hang the knife with the knife change facility onto the bolts of the knife lift.

4. Remove the knife handles and the knife change facility C

5. Wind the knife up to the top dead center using the knife lift .

Attention!
Is the knife tight when you wind it up?
Possible cause: Warped knife!
Do not force the knife upward! This may damage the knife lift.
Remedy: Use another knife.
Check, if problematic knife is even (over the entire length of the knife).
Have the knife straightened, if necessary.

6. Lightly screw-in the knife screws into the lower line of drilled mounting
holes. Firmly tighten the two knife screws (d)!
(When dealing with worn knives, please notice: If the knife height is less
than 95 mm, use the upper mounting holes!) d

K6 - 18
6.0 Knife change
Knife Change "OptiKnife" on Types 78 and 92

19

7. Close the knife change flap (19) and press the cut buttons.
< The knife bar moves to the lower final position>.
Lightly screw-in the outer left-hand knife screw (model 92: 2 knife screws).
Unscrew the two knife screws (d)! d
b y c
8. Push some paper strips under the knife, on the left and right.

9. Use the adjusting wrench to lower the knife lift onto the cutting stick
Turn the supporting cams (b, first the left, than the right one) clockwise up to
the stop.
Tighten the retaining screws of the supporting cams (a)!
Firmly tighten all of the knife screws, from centre towards both ends
alternately by means of T-wrench (except the screw on the very right).

10. Press the cut buttons < the knife bar is moved upward >
Open the knife change flap.
Firmly tighten the knife screw on the very right.
Close the knife change flap. a

11. Make a check cut:

Press the cut buttons < the knife bar is moved to its lowest position >

Have the paper strips been cut through? If so:

Press the cut buttons again < the knife bar is moved upward >
On the display. Select "Finish the knife change"*
< The "Program Data" menu is indicated >
* on X-machine: enter number via numerical keyboard
on XT-machine: touch line in the display

K6 - 19
 6.0 Knife change
Knife Change "OptiKnife" on Types 78 and 92

If the paper strips have not been cut through: * on X-machine: enter number via numerical keyboard
on XT-machine: touch line in the display
12. Use the adjusting wrench to slacken the fixing device of the eccentric bolt
(y) by approximately one turn.
Turn the eccentric bolt (c) clockwise.
Tighten the fixing device (y) at the eccentric bolt.

13. Make a check cut:

Have the paper strips been cut through now? If so:

Press the cut buttons again < the knife bar is moved upward >
On the display. Select "Finish the knife change"*
< The "Program Data" menu is indicated >

Attention! Subsequent to every knife change, check breaking pin.

If necessary, tighten it.

K6 - 20
6.0 Knife change
Changing of Cutting Stick

POLAR cutting sticks are made of tough plastic material.

Through its wavy shape it will stay in the table groove without glue or screw.

By turning each cutting stick can be used four times.

Removing of cutting stick

1. Pull the lever (A) on the left gauge to the front

< cutting stick will be lifted on the left (B) > normal turnover replace

2. Remove cutting stick from left to right.

Clean groove thoroughly!

Inserting of cutting stick

1. Push end of cutting stick against right side catch (C) and into groove. A

2. Following its wavy shape continue pressing stick firmly into groove from
right to left.

K6 - 21
K6 - 22
7.0 Malfunctions / Breakdowns

K7 -1
 7.0 Malfunctions/Breakdowns
Mechanical Breakdowns

Breakdown: Knife gets stuck during cut Main switch

78 / 92
ON
Remedy: Manual knife cycle
OFF 1
Cause: • Knife is dull o r
• Knife has unsuitable knife angle

Procedure:

15
0
35
50 00
0

1000

1. Cutting has to be stopped immediately either by releasing of cut 3000

1500

buttons or switching off the automatic cycle.

2000
2. Turn off machine . Main switch
115 - 176
3. Turn main switch (2) to "0" position.

4. Hook the padlock in the main switch, lock it and remove the key

15
0
35
50 00

ON 0

5. Attention! Wait until motor or main wheel has 1000

come to a complete standstill! OFF

1500
3000

Remove cover from clutch guard

2000
6. Insert clutch handles into holes (A) and tighten them; in addition, on types
115 - 176: attach turning handles onto clutch handles
Drive guard
7. Turn main wheel counter-clockwise to raise knife to upper final position

8. Remove clutch (and turning) handles

A
A
9. Attach cover to clutch guard

10. Unlock and remove the padlock from the main switch

11. Turn main switch to " I " position

Note:
The manual knife cycling cannot be started from the "upper resting position".
Before the machine is turned off the knife must be inched half way down with the
cut buttons.

K7 -2
7.0 Malfunctions/Breakdowns
Cont.: Mechanical Breakdowns

Breakdown: Shear bolt in connecting rod is broken

Cause: Overloaded

Remedy: Replace shear bolt

Attention! Do not remove the cutting material from the

table before the two cut buttons have been pressed again!
Risk of injuries caused by lowering knife bar!

Procedure (to be observed absolutely!):

1. Return knife bar and clamp to "upper final position" by pressing the
cut buttons!

2. Remove stock from table. 46

47
3. Remove access cover at front panel.

4. Remove broken shear bolt parts (46).

48

5. Insert new shear bolt*

6. Re-tighten shear bolt nut (47) after approx. 50 cuts.

7. Re-position access cover.

* Note! Mount shear bolt nut always in lower part of con-rod (48).

Attention!
In case shear bolt was broken because knife bar hit safety bolt this is a
malfunction which can only be eliminated by a service engineer!

K7 -3
 7.0 Malfunctions/Breakdowns
Electrical Malfunctions / Breakdowns

Electrical malfunctions of the machine will appear in the status display in plain
text.
The operator is warned by a beep sound.

In that case, the operator has to decide whether it is an

• operation error,
• programming error,
• malfunction of the machine.

Remedy for operating error (programming error):

• Check program data or input, resp.

• Correct any mistakes

Remedy for machine malfunctions:

• Turn machine off and on again

if error message has disappeared:

• Resumen function

if error message appears again:

• Call service technician, indicate the error message

K7 -4
7.0 Malfunctions/Breakdowns
Start - Up Breakdown: Scan Reference Point / Auxiliay Mode

Malfunction: After machine has been started, screen displays:

"ACTUAL POSITION OF BACKGAUGE UNKNOWN"

Cause: Machine was shut off during backgauge movement

Remedy: Scan reference point

1. Select "Scan reference position"

< Prompt appears: clear the table >

2. Select "Confirm when table empty"

< Prompt appears: go to nominal position >

3. Use handwheel or press any of the backgauge movement keys

< Backgauge moves to reference point >

Reference run can be interrupted by pressing key !

If reference point is found:

< menu display "Correction of basic position" >

4. Check basic position and confirm or enter new basic position

(see page K5B - 35)
< Program Data display appears >

K7 -5
 7.0 Malfunctions/Breakdowns
Auxiliary Mode

If the reference point scanning fails

1. Shut off machine and turn on again

< menu "Reference mode" appears >

2. Select "Auxiliary operation, no cut"

3. Menu "Select cutting width" appears:

Select machine type!

Machine functions possible in auxiliary operation:

• Cutting
• Backgauge movement with handwheel or backgauge movement keys

K7 -6
8.0 Maintenance

Prior to any maintenance work, cut off machine and disconnect power supply.
Attention!

All the cables marked with the symbol , as well as any cables with orange
sheath are still alive even if the main switch has been shut off.

K8 - 1
 Basic information about servicing and maintenance work

• Always turn off the machine and disconnect the power supply before • In the event of defective safety equipment, e.g. safety light barriers,
undertaking any maintenance work. protective covers, etc., the machine/system must be taken out of
operation and repaired immediately.
Warning!
All the cables marked with the symbol , as well as any cables
• All safety signs on the machine/system must be in impeccable and
with orange sheath are still alive even if the main switch has been
easily identifiable condition. Replace safety signs if this is not the
shut off.
case.

• Once the plant is turned off, prevent it from being turned back on
• Proceed as follows if maintenance work necessitates stepping onto
again by blocking the relevant main switch. If necessary, warning
individual system components, e.g. lubrication of gripper compon-
signs should also be put up at the main switches to alert others to
ents on the cutting machine rear table or conveyor lines:
maintenance work in progress.
Before stepping onto conveyor units, pallets or cutting machine rear
table:
• Due to the need for special tools, we recommend that maintenance
Cover surfaces to be stepped on with cardboard and secure
and lubrication work be carried out by the POLAR After-Sales Ser-
cardboard in place with adhesive tape.
vice.
Warning! Slippery underfooting: Risk of slipping!
After finishing the works:
Totally remove cardboard and adhesive tape as well as any remains
• The product recommendations contained in these operating
of adhesive tape from the surfaces.
instructions, e.g. for oils and greases, may be regarded as up-to-date
at the time of going to press.
We cannot guarantee either the correctness or completeness of
• For lubrication dismantle any guards at the guide units. Assemble
these instructions. The user is responsible for ensuring compliance
the guards immediately after the maintenance work has been
with all the applicable laws and regulations before using these
performed (Safety!).
products. To ensure this, the relevant technical and safety data
sheets should be obtained from the appropriate manufacturers
before use. The user is advised to meet his obligations in respect of
• After lubrication:
product observation, and to exercise due care when using the
Use a rag to remove any excessive lubricant (greases, oils)
products.
completely which seeps out, especially above the table surfaces that
Polar will not be held responsible for any kind of damage or injury
contact the material to be cut.
due to failure to comply with the descriptions provided by the
various manufacturers, or due to the risks associated with the nature
of the product
• The specified maintenance intervals are based on an operating time
of 8 hours / day. For multi-shift operation the maintenance intervals
need to be adapted correspondingly.
• Compliance must be assured with the legislation on electrical plants
or systems, hydraulic and/or pneumatic equipment as applicable in
the country of use.

K8-2
HYDRAULIC (all types) Usable oil brands (DIN 51524, in alphabetical order):

We recommend to have oil changed and unit checked by ARAL Vitam GF 46 FUCHS Renolin B, rot
POLAR and/or authorized personnel. AGIP Oso 46 KLÜBER Lamora HLP 46
BP Energol HLP-HM 46 MOBIL DTE 25
Attention when bleeding hot oil - danger of burning! CASTROL Hyspin SP 46 SHELL Tellus C 46
DEA Astron HLP 46 TOTAL Azolla ZS 467
Hydraulic unit mounted inside right frame pillar ESSO Nuto H 46
ELF Elfolna 46
Oil change: approx. every 6000 hrs. FINA Hydran AF 46
further: • replace oil filter Quantity (liters): 30 liters / 8 US gal (115, 137, 155, 176)
• remove any suds from bottom of oil tank. 23 liters / 6 US gal (92)
10 litres / 2,6 US gal (78)

GEAR (all types) Usable oil brands (DIN 51517, in alphabetical order):

ARAL Degol BG 220 ELF Olna 220

Check oil level monthly!
AGIP Blasia 220 FINA Giran 220
BP Energol GR-XP 220 KLÜBER Klüberoil GEM1-220 N
First oil change: after approx. 500 hrs.
CASTROL Alpha SP 220 or MOBIL Mobilgear 630
Optigear BM 320 SHELL Omala 220
Attention when bleeding hot oil - danger of burning!
DEA Falcon CLP 220 TOTAL Carter EP 220
ESSO Spartan EP 220
Fill oil to the middle of oil sight glass.
Quantity (liters/pints): 78 - ca 1 / 2
92 - ca 0,7 / 1.1
115 - ca 1,2 / 2 1/2
137 - ca. 1,6 / 3 1/3
155/176 - ca 2,5 / 5 1/4

BACKGAUGE GUIDE RAILS ( only 78, 92, 115, 137, 155) Usable grease brands (DIN 51825, in alphabetical order):

Grease lubrication! ARAL Radlagerfett ESSO Unirex N2 or

Lubrication by means of grease gun via 2 lubricating nipples on the backgauge AGIP Autol Top 2000 or Essonorva 275
of the cutting machine. Longtime Grease 2 FINA Pluton AX 2
BP Energrease LS-EP 2 or KLÜBER Centoplex 2 EP
Intervals of lubrication according to lubrication chart at machine! BP Energrease LZ 2 MOBIL Mobilgrease XHP 222
2-3 strokes with grease gun are sufficient for lubrication. CASTROL Longtime PD 2 SHELL Retinax LX 2
DEA Paragon EP 2 TOTAL Multis EP 2

K8 - 3
 GUIDING GIBS; GUIDING GROOVES FOR KNIFE AND CLAMP; Usable grease brands (DIN 51825, in alphabetical order):
ECCENTRIC BOLT; CRANK PIN
ARAL Radlagerfett ESSO Unirex N2 or
AGIP Autol Top 2000 or Essonorva 275
Greasing according to lubrication schedule of machine. Longtime Grease 2 FINA Pluton AX 2
2 - 3 strokes with grease gun are sufficient. BP Energrease LS-EP 2 or KLÜBER Centoplex 2 EP
BP Energrease LZ 2 MOBIL Mobilgrease XHP 222
CASTROL Longtime PD 2 SHELL Retinax LX 2
DEA Paragon EP 2 TOTAL Multis EP 2

CENTRAL LUBRICATION
(On type 176 standard equipment;
special equipment on types 115/137/155)

The central lubrication supplies the sliding panels of knife bar, the guideways of
knife bar and clamp, eccentric bolt, crank pin as well as the backgauge guiding
rails and spindle with grease.
The central lubricating nipple is located under the access hole lid (1).
Lubrication with grease cartridges in high-pressure lever type hand gun.
Distribution to the lubricating points is done by a progressive distributor.

Maintenance intervals: Weekly

1. Switch-on machine

2. Press the lever of the type hand gun until service window appears in the
display with the message "STOP! SUFFICIENT LUBRICATION!"

3. Switch-off machine

K8-4
BLOWER FILTER / VENTILATION FILTER AT THE CONTROL BOX

A Check the filter of the blower air-intake fittings every month, and clean
them, if necessary.

B Check the ventilation filter at the control box every month, and clean it, if
necessary. For this purpose:

1. Remove the front covers (beneath the front table)

2. Pull the ventilation filter out forward (at control box on rh and lh side)
3. Check the filter and clean or replace it, if necessary

CRANK ARM HOUSING

Examine the crank arm housing (2, behind the access hole lid). Remove any 2
existing dirt and remaining paper.

Maintenance interval: every month

BATTERIES FOR DATA STORAGE

To be replaced only by POLAR service or agencies Batteries inside machine are used for data storage
Replacing after approx. 5 years

CLEANING OF DISPLAY

1: Turn off machine

2. Use glass cleaner and soft lint-free rag.

MAINTENANCE INTERVALS 8 hrs. per day equal:

500 = 3 month (gear oil)

Maintenance by POLAR service!
6.000 = 3 years (gear /hydraulics)
10.000 = 5 years (batteries)
Please call for maintenance or service ahead of due date!
18.000 = 9 years
The address of the representation can be read from the plate on the machine.
24.000 = 12 years

K8 - 5
 Cutter AUTOTRIM 80

POLAR AUTOTRIM is driven pneumatically.

The pneumatic system may only be connected to compressed-air systems

or compressors fitted with pressure relief device!

Max. pressure: 10 bars

Operating pressure: 5 - 6 bars
Operating pressure is set at the compressed-air conditioning unit.

Maintenance of Autotrim compressed-air system:

requiring no maintenance!

Maintenance of table guidings

Guidings of the Autotrim front table

Interval of maintenance:
X
with daily 8-hour operation: weekly
With multi-shift operation the lubrication must be
performed correspondingly at shorter intervals.

Lubrication is done via grease nipple (x) by means of grease gun at the left and Usable grease brands (DIN 51825, in alphabetical order):
right-hand crossheads of the front table.
ARAL Radlagerfett ESSO Unirex N2 or
AGIP Autol Top 2000 or Essonorva 275
Longtime Grease 2 FINA Pluton AX 2
BP Energrease LS-EP 2 or KLÜBER Centoplex 2 EP
BP Energrease LZ 2 MOBIL Mobilgrease XHP 222
CASTROL Longtime PD 2 SHELL Retinax LX 2
DEA Paragon EP 2 TOTAL Multis EP 2

K8-6
GRIPPER LOADING SYSTEM "GF"

The Polar Gripper System GF must be lubricated at the following Usable grease brands (DIN 51825, in alphabetical order):
lubricating points:
ARAL Radlagerfett ESSO Unirex N2 or
A Gripper guides (circular guiding) AGIP Autol Top 2000 or Essonorva 275
Longtime Grease 2 FINA Pluton AX 2
Lubrication is performed with grease gun via lubricating nipples. After BP Energrease LS-EP 2 or KLÜBER Centoplex 2 EP
that, carry out a gripper motion BP Energrease LZ 2 MOBIL Mobilgrease XHP 222
CASTROL Longtime PD 2 SHELL Retinax LX 2
Maintenance interval: DEA Paragon EP 2 TOTAL Multis EP 2

with 8 hours of operation per day: every 6 months

With multi-shift operation the
lubrication must be carried out more
frequently according to the
requirements.

B Gripper guiding (driving chain)

Brush the driving chain with a coat of grease and then carry out a gripper motion.

Maintenance interval:

with 8 hours of operation per day: every 6 months A

With multi-shift operation the lubrication
must be carried out more frequently
according to the requirements.
B

K8 - 7
 Index
A Clamp Pressure Adjustment K4 - 4
Clamp unit at Backgauge K5C - 21
Accident prevention warning labels K1 - 8 Clamp unit at knife K5C - 8
Additional Functions K5B - 1, K5C - 1 Clamp unit in front of knife K5G - 4
Adjustment of knife bar on types fitted with con-r K6 - 14 Clamping and Cutting K4 - 3
After the Installation of the Machine K1 - 4 Clamping with False Clamp Plate K4 - 6
Air supply complete air table OFF K5C - 3 Clamping without cutting K5C - 3
Air supply complete air table ON K5C - 3 Cleaning of Display K8 - 5
Air supply front table ON K5C - 3 Compensation of Variations in Print K5A - 38
Air Table K4 - 7 Configure air push button K5B - 34
Automatic Backgauge Adjustment through Numerical K K5A - 10 Control Panel 78 ED E - 5
Automatic clamp pressure adjustment K5G - 2 Copy a Program Within Memory Segment A or B, Resp K5B - 5
Automatic Knife ACTIV K5C - 4 Copy Program K5B - 4
Automatic Knife OFF K5A - 24 Copy Program Steps into Clipboard K5A - 20
Automatic Knife PREPARED K5C - 4 Copy Several Programs Within Memory Segments A or K5B - 6
Automatic ON/OFF (Automatic Forward) K5A - 23 Copying of Complete Memory into Second Memory K5B - 7
Automatic Operation K5A - 1 Copying of One/Several Programs into Second Memory K5B - 6
Autotr. / Align material K5C - 5 Correcting a Step of Block Programming K5B - 18
Auxiliary Functions: PL-Block Branch Table K5F - 5 Correction for Material K5B - 40
Auxiliary operation without actual position K5B - 28 Correction of an Input Error K5A - 22
B Correction of Cut Position K5F - 4
Correction of Position K5F - 7
Backgauge advance "slow" K5C - 6 CountMonitor E - 14, K5F - 8
Backgauge Deceleration K5G - 2 Cursor "input" K5A - 9
Backgauge Guide Rails K8 - 3 Cursor Movement in Basic Display K5A - 9
Backgauge Speed K5G - 2 Cursor "step" K5A - 9
Basic Display: Function Survey K5A - 8 Cut and Record K5F - 3
Basic Display: Program - Information K5A - 6 Cut Correction K5A - 41
Basic Display: Program Survey K5A - 7 Cutting line indicator, mechanical with clamp K4 - 3
Basic Display: Program-Data K5A - 4, K5A - 5 Cutting line indicator, optical K4 - 3
Batteries for Data Storage K8 - 5
Bedienpult POLAR 92 - 176 ED E - 14 D
Block Programming K5B - 8 Define Operators K5B - 37
C Define Time Assignments K5B - 37
Deleting a Stored "Swivel Backgauge" Function with K5C - 16
Calculator Functions K5A - 39 Deleting a Stored "Tilting Backgauge" Function wit K5C - 18
Calling a Step of a Block Programming K5B - 18 Deletion of a Program K5A - 29
Central Lubrication K8 - 4 Deletion of a Step Number (Measurement/Comment) K5A - 28
Changing of Cutting Stick K6 - 21 Deletion of a Wrong Input K5A - 11
Chapter survey E - 18 Deletion of Several Step Numbers (Program Section) K5A - 28
Clamp Light Barrier K5G - 3 Determination of Remaining Measurement with ELTROT K5D - 9

K8-8
Index
Difference Formation K5F - 3 J
DIN Sheet Sizes A K5B - 23
DIN Sheet Sizes B K5B - 23 JIS sheet sizes B K5B - 23
Display of Optional Equipment K5C - 14 Jogging mark K5C - 6
DNF - Modul E - 7 K
E Knife Change K6 - 1
EasyMode E - 13, K5C - 10 Knife Change from the Front Side on Types 115, 137 K6 - 2, K6 - 3,
EC-Conformity Declaration K1 - 12 K6 - 4, K6 - 5, K6 - 6, K6 - 7
Ejector OFF K5C - 6 Knife Change with Con-Rod Adjustment on Types 115, K6 - 8
Electrical Malfunctions/Breakdowns K7 - 4 Knife Thickness Compensation (Calibration) K5B - 24
Erase Step(s) With Number(s) K5A - 18 Korrektur - Modul E - 7
Explanation of Pictographs on the Display E - 15 L
External Additional Functions K5B - 32, K5E - 2
External Additional Functions: Optional Equipment K5E - 4, K5E - 5 Language K5B - 3
Lay guide I K5C - 5
F Lay guide II K5C - 5
Fixomat K5C - 19 Legal Provisions K1 - 10
Flexible False Clamp Plate K4 - 6 Light Barrier K4 - 4
Functional Comments K5D - 4 List of Additional Functions K5C - 3
Functions of the Menu Keys K5A - 3 List of knife corrections K5B - 38

G M
Gear (Maintenance) K8 - 3 Machine Layout K1 - 2
Gripper Loading System G K5E - 4 Main Menu (Function Survey) K5B - 2
Gripper Loading System GF K5E - 5 Maintenance K8 - 1
Guiding Gibs; Guiding Grooves For Knife and Clamp; K8 - 4 Maintenance Cut Counter K5B - 25
Malfunctions/Breakdowns K7 - 1
H Manual Operation K4 - 1
Measurement Display and Measurement System K3 - 3, K3 - 4
Highspeed Cutting K5G - 3
Measurement Input in Inches K5A - 10
Hydraulic (Maintenance) K8 - 3
Measurement Input with Metric System K5A - 10
Hydraulic Data K1 - 10
Measuring Unit K5B - 3
I Mechanical Breakdowns K7 - 2
Menu Key: Auxiliary Functions K5F - 1
Inch sheet sizes K5B - 23 Menu Key: External Additional Functions K5E - 1
Input Error K5A - 11 Menu Key: Program Functions K5D - 1
Insert/Append from Clipboard K5A - 21 Menu Key: User Defined Additional Functions K5H - 1
Inserting of Measurements into a Program K5A - 36
Introduction E - 19, K5A - 2 N
Negative Sign K5A - 40

K8 - 9
 Index
Nominal Position K5D - 2 Safety Relevant Machine Elements K1 - 6, K1 - 8
Safety Signs K1 - 9
O Safety Signs (for U.S. and CAN. specifications onl K1 - 8
Operating Elements E - 6 Save a hold-down clamp function E - 9
Optimization of clamp K5G - 3 Selecting a Program K5A - 13
Order Printing (Production Report) K5B - 22 Selection of a Free Program K5A - 12
Order Readout (Production Report) K5B - 22 Service K5B - 23
Overflow Indicator K5A - 39 Setting of measurements (backgauge movement) by ha K4 - 2
Setting the Clamping Time K4 - 4
P Setting Up a Cutting Program, Example 1 K5A - 16
PL-Block Branch Table K5F - 5 Setting Up a Cutting Program, Example 2 K5A - 17
Place of Installation K1 - 4 Sheet offset sizes K5B - 23
Plan K1 - 3 Sheet Size Tables K5B - 23
Positioning K5A - 11 Simulation without Cuts K5F - 2
Power Supply K1 - 5 Skip Cutting Warning On K5F - 4
PowerMonitor E - 13 Smooth Prepressure K5G - 3
Prepressing Time Before Cut K5G - 2 Special Function Moduls at the Operating Panel E - 7
Preset Cut Counter K5B - 26 Stack Lifts, fixed with Semi-Automatic Height Cont K5C - 28
Preset Functions K5B - 27 Standard sizes K5B - 23
Press Material (Fix Clamp) K5B - 39 Start - Up K3 - 1
Pressing Time No Cut K5G - 2 Start - Up Breakdown: Scan Reference Point/Auxilia K7 - 5
Production Report K5B - 21 Step Selection K5A - 18
Program Examples with ELTROTACT K5D - 8 Storage of a Clamp Unit at Knife Function K5C - 26
Program Functions K5D - 1 Storage of Additional Functions with Cut Size K5C - 2
Program Loop K5D - 6 Storage of Comments K5D - 3
Program Parameters K5D - 11 Storage of Measurements K5A - 15
Program Protection K5F - 2 Storage of Program Informations K5A - 26
Programmable Ejector K5D - 5 Storage of Swivel Backgauge Function K5C - 15
Storing of Measurements According to printed Image K5A - 37
R Storing of Program Informations K5A - 27
Storing the "Tilting Backgauge" Function K5C - 17
Repeat Block - Automatic Repetition K5D - 9
Subsequent Storage of a Clamp Unit at Knife Funct K5C - 26
Repeat Cut Device ELTROTACT K5D - 7
Subsequent Storage of a Swivel Backgauge Function K5C - 16
Retractable Side Gauge K5C - 27
Subsequent Storage of a Tilting Backgauge Function K5C - 18
Running a Cutting Program K5A - 25
Subsequent Storing of a Comment into an Existing P K5D - 4
S Subsequent Storing of Additional Functions K5C - 2
Subsequent Storing/Erasing of External Additional K5E - 3
Safety K2 - 1
Switching air supply off K4 - 7
Safety Auxiliary Tools K1 - 7
Switching air supply on K4 - 7
Safety Inspection (only in Germany) K1 - 10
Switching Machine ON K3 - 2
Safety Precautions K1 - 10

K8-10
Index
T
Table of contents E - 2, E - 3
Technical Data K1 - 10, K1 - 11
Time to align or remove K5G - 4
Touch-Screen Calibration E - 9
Transform ET-Block Using Absolute Positions K5A - 20
Transport and Installation of the Machine K1 - 4
Turning Gripper K5E - 10
Turning Machine OFF K3 - 2
TwinClamp K5C - 23
Type Plates K1 - 5
U
User Defined Additional Functions K5H - 1
User Defined Comments K5B - 32, K5D - 3
Using Backgauge Position of Calculations K5A - 40
W
Working Area of Operating Personnel K1 - 7

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They are not to be copied or made known to others, without
express agreement, regardless of what form they might take.
Violations will entail liability for damages.

K8 - 11
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Printed in Germany
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08/78/Ho/(V 1.5.0)
78X/XT - 7861501
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