Operating InstructionsControl Panel 92 - 176 E / 92 - 176 ED..........................................................E - 4 Control Panel 78 ED ......................................................................................E - 5 Operating Elements .......................................................................................E - 6 Special Function Moduls at the Operating Panel ...........................................E - 7 DNF - Modul...................................................................................................E - 7 Correction - Modul..........................................................................................E - 7 Keypad ED-COLOR ......................................................................................E - 8 Explanation of Pictographs on the Display.....................................................E - 10 Chapter survey ...............................................................................................E - 13 Introduction ....................................................................................................E - 14 Technical Data/Machine Layout/Transport and Installationof the Machine/Safety Relevant Machine Elements...............................K1 - 1 Machine Layout............................................................................................K1 - 2 Plan..............................................................................................................K1 - 3 Transport and Installation of the Machine....................................................K1 - 4 Place of Installation......................................................................................K1 - 4 After the Installation of the Machine.............................................................K1 - 4 Power Supply...............................................................................................K1 - 5 Type Plates..................................................................................................K1 - 5 Safety Relevant Machine Elements.............................................................K1 - 6 Technical Data..............................................................................................K1 - 8 Permissible Environmental and Operating Conditions.................................K1 - 8 Hydraulic Data..............................................................................................K1 - 8 Safety Precautions.......................................................................................K1 - 8 Safety Inspection (only in Germany)............................................................K1 - 8 Legal Provisions...........................................................................................K1 - 8 Technical Data..............................................................................................K1 - 9 Accident prevention warning labels at POLAR cutters (for U.S. and CAN. specifications only).....................................................................................K1 - 10 Safety Relevant Machine Elements...........................................................K1 - 10 Safety.........................................................................................................K2 - 1 Start - Up....................................................................................................K3 - 1 Switching Machine ON.................................................................................K3 - 2 Turning Machine OFF..................................................................................K3 - 2 Measurement Display and Measurement System........................................K3 - 3 Manual Operation......................................................................................K4 - 1 Fine Adjustment by Hand.............................................................................K4 - 2 Setting of Measurements (Backgauge Movement) by Hand........................K4 - 2 Cutting Line Indicator, Mechanical with Clamp............................................K4 - 3Cutting Line Indicator, Optical......................................................................K4 - 3 Clamping and Cutting...................................................................................K4 - 3 Clamp Pressure Adjustment.........................................................................K4 - 4 Setting the Clamping Time...........................................................................K4 - 4 Light Barrier..................................................................................................K4 - 4 Flexible False Clamp Plate (Optional Equipment).......................................K4 - 6 Clamping with False Clamp Plate................................................................K4 - 6 Air Table.......................................................................................................K4 - 7 Automatic Operation...............................................................................K5A - 1 Introduction...............................................................................................K5A - 2 Functions of the menu keys......................................................................K5A - 3 Basic Displays...........................................................................................K5A - 4 Basic Display: Program-Data....................................................................K5A - 4 Basic Display: Program - Information.......................................................K5A - 6 Basic Display: Program Survey................................................................K5A - 7 Basic Display: Main Menu (Function Survey)...........................................K5A - 8 Cursor Movement in Basic Display...........................................................K5A - 9 Automatic Backgauge Adjustment through Numerical Keyboard............K5A - 10 Deletion of a Wrong Input in Input Section..............................................K5A - 11 Moving Backgauge to a Nominal Position (Positioning)...........................K5A - 11 Input Error: Value of Nom. Backgauge Position too Low/High.................K5A - 11 Selection of a Free Program...................................................................K5A - 12 Storage of Measurements.......................................................................K5A - 15 Setting Up a Cutting Program, Example 1..............................................K5A - 16 Setting Up a Cutting Program, Example 2..............................................K5A - 17 Step Selection.........................................................................................K5A - 18 Step Selection.........................................................................................K5A - 18 Delete Step Number(s)...........................................................................K5A - 18 Enter Additional Functions......................................................................K5A - 19 Erase Additional Functions......................................................................K5A - 19 Step Selection.........................................................................................K5A - 19 Correction of an Input..............................................................................K5A - 20 Automatic ON/OFF (Automatic Forward)................................................K5A - 21 Automatic Knife OFF..............................................................................K5A - 22 Running a Cutting Program.....................................................................K5A - 23 Storage of Program Informations............................................................K5A - 24 Deletion of a Step Number (Measurement/Comment)............................K5A - 26 Deletion of Several Step Numbers (Program Section)...........................K5A - 27 Deleting a Program / Several Programs.................................................K5A - 28 Inserting of Measurements into a Program.............................................K5A - 30 Storing of Measurements According to Printed Image............................K5A - 31 Compensation of Variations in Print........................................................K5A - 32E - 2Calculator Functions...............................................................................K5A - 33 Negative Sign..........................................................................................K5A - 34 Using Backgauge Position of Calculations..............................................K5A - 34 Cut Correction.........................................................................................K5A - 35 Machine Functions and Additional Functions.....................................K5B - 1 Main Menu (Function Survey)...................................................................K5B - 2 Language..................................................................................................K5B - 3 Measuring Unit..........................................................................................K5B - 3 Copy Program...........................................................................................K5B - 4 Printer........................................................................................................K5B - 8 Block Programming.................................................................................K5B - 10 Selection of an Input Parameter with Block Programming......................K5B - 20 Correction of an Input Parameter with Block Programming....................K5B - 20 PMS-Card...............................................................................................K5B - 21 Production Report...................................................................................K5B - 24 Sheet Size Tables...................................................................................K5B - 26 Service....................................................................................................K5B - 26 Knife Thickness Compensation...............................................................K5B - 27 Maintenance Cut Counter.......................................................................K5B - 28 Preset Cut Counter..................................................................................K5B - 29 Preset Functions.....................................................................................K5B - 30 Press Material (Fix Clamp).....................................................................K5B - 41 Correction for Material............................................................................K5B - 42 Menu Key: Additional Functions...........................................................K5C - 1 Storage of Additional Functions with Cut Size..........................................K5C - 2 Subsequent Storing of Additional Functions.............................................K5C - 2 List of Additional Functions.......................................................................K5C - 3 Display of "Optional Equipment" (option)...............................................K5C - 10 Swivel Backgauge (optional equipment).................................................K5C - 11 Tilting Backgauge (optional equipment)..................................................K5C - 13 Fixomat (optional equipment).................................................................K5C - 15 Clamp unit at Backgauge (optional equipment)......................................K5C - 17 Retractable Side Gauge (Option)............................................................K5C - 19 Stacklifts, Fixed.......................................................................................K5C - 20 Menu Key: Program Functions..............................................................K5D - 1 Nominal Position.......................................................................................K5D - 2 Storage of Comments...............................................................................K5D - 2 Subsequent Storing of a Comment into an Existing Program...................K5D - 4 Programmable Ejector..............................................................................K5D - 5 Program Loop...........................................................................................K5D - 6Repeat Cut Device ELTROTACT..............................................................K5D - 7 Program Examples with ELTROTACT......................................................K5D - 8 Determination of Remaining Measurement with ELTROTACT.................K5D - 9 Repeat Block - Automatic Repetition........................................................K5D - 9 Program Parameters...............................................................................K5D - 10 Menu Key: External Additional Functions............................................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 Menu Key: Auxiliary Program Functions.............................................K5F - 1 Set/Delete Program Protection.................................................................K5F - 2 Simulation without Cuts.............................................................................K5F - 2 Cut and Record.........................................................................................K5F - 3 Difference Formation................................................................................K5F - 3 Correction of Cut Position.........................................................................K5F - 4 Skip Cutting Warning On..........................................................................K5F - 4 Progress Control.......................................................................................K5F - 5 Correction of Position................................................................................K5F - 5 Menu Key: Machine Parameters (Program-/Step Parameter).............K5G - 1 Functions of the "Machine Parameters" (Program-/Step Parameter) menu.........................................................................................................K5G - 2 Knife Change.............................................................................................K6 - 1 Knife Change with Con-Rod Adjustment on Types 115, 137, 155................K6 - 2 Adjustment of knife bar on types fitted with con-rod adjusment...................K6 - 9 Knife Change from the Front Side on Type 78 and 92...............................K6 - 10 Adjustment of knife bar on type 78............................................................K6 - 16 Knife Change from the Front Side on Types 115, 137, 155, 176...............K6 - 17 Changing of Cutting Stick..........................................................................K6 - 23 Malfunctions/Breakdowns.......................................................................K7 - 1 Mechanical Breakdowns...............................................................................K7 - 2 Electrical Malfunctions/Breakdowns.............................................................K7 - 4 Start - Up Breakdown: Scan Reference Point / Auxiliay Mode....................K7 - 5 Auxiliary Mode.............................................................................................K7 - 6 Maintenance..............................................................................................K8 - 1E - 3Control Panel 92 - 176 E / 92 - 176 EDE - 4Control Panel 78 EDE - 5Operating ElementsE - 6Special Function Moduls at the Operating PanelE - 7E - 8Simulation of graphic program cyclepressing the backgauge movement key …Backgaugeslow advance“. Every time the key is pressedlabel group by label group or label by label will beprocessed graphically.A line indicates the cutting line. The cutting sectionis visually emphasized.E - 9E - 10Explanation of Pictographs on the DisplayPre-clamping timeClamping grade parametersExternal special functionsFeed markProgrammable ejectorServo ramp increaseServo ramp decreaseFixomat ON front marginFixomat ON side marginPage backTilting backgaugeSwivel backgaugeHolding-down clamp active/passiveHolding-down clamp activeAutotrim Vordertisch hebenSSide gauge /both downwardSide gauge /left downwardAutomatic knife preparedLay guide ILay guide IIAdditional functionsProgram functionsRear table air OnAuxiliary functionsAutotrim front table loweringPaper sizesKey Automatic knife OffLayer countingClamping without cut activeKey EnterKey CorrectionKey DeleteKey InsertKey MemoryKey Memory ReadPositioningKey equalsKey Program selectionKey Step selectionKey Program Data displayKey Program InformationKey Function SurveyKey Program SurveyAutomatic knife activeNominal positionMeasuring unitFunction commentsMaterial correctionLS - Label sizeLQ - Label quantityTC - Total cutsKeys Cursor right/leftFix clampKey Cursor Up/DownHelpKey Cursor HomeNumerical keyboardHand wheelClamping grade 0 - 9Backgauge advanceBackgauge reverseCut buttonsExt. add. function aktive upon start-upExt. add. function aktive upon stopMarking during cuttingDifference formationKey Actual to nominal positionSet program protection/OnBackgauge advance slowAutotrimClamping without cuttingAutomatic ejector offComplete air off Complete air onE - 11Front table air onClamping grade 0 - 9/sensorKnife changeProgram loopFunction survey/memory/copyFunction survey/languageKnife thickness correction listFunction survey/serviceFunction survey/block programmingFunction survey/ pre-adjust functionsParameter listFunction survey/produktion reportFixomat, generalSwivel backgauge, generalTilting backgauge, generalHolding down clamp, generalSide gauge, generalCutting optimization or clampoptimizationCutting optim./smooth preclampingCutting optim./high-speed cuttingCutting optim./clamp light barrier/elevatingtimeTurn cw by 90°Turn ccw by 90°Turn by 180°Put asideFeedKey figure 1 (num. keyboard)ClearService menuCall serviceErrorClamping grade/sensorsSmooth braking to stop Yes/NoReference runCorrect basic positionCorrect actual positionPress materialGerman/nationalityComment selectionComment inputSimulation Eltrotact Total cutProgram protection seting/deletePlease waitDown Load CardClamping without cut/clamping timeClear input or page backBackgauge keys, generalTable of clamping gradesBackgauge speed/gradeSmooth braking to stopAutotrim Blowing air, OnAutotrim Blowing air Start/EndParameterliste/CopyPMS CardCursor (78ED only)Block programming: label incl.marginBlock programming: label withoutmarginBlock programming: optimizationstageBlock programming:utilizationMain drive unit not readyPress pedalAutotrim, last margin cutAutotrim, last labelAutotrim, adjust/ejectionOrderDelete stepSelect stepCorrect/insert Additional functionsDelete Additional functionsLook for orderSelect program number Delete program numberE - 12Under cutAuxiliary operationPlus/Positve signMinus/negative signSimulation of cutting sequenceWarning On: skip cuttingin automatic op.: corr. of nom.positionWarning Off: skip cuttingCommentsPrintingKnife support plate OnKnife support plate OffChange contrast of displayKnob distorsion correctionKnob label correctionPMS Card machine dataCursorsubstitution left/right Align/put aside material withoutAutotrimOriginal sheet size (blockprogramming)Label size (block programming)Data ControlEdge trim (block programming)Subtraction repetitionGraphic OffKnife lower dead point/timeCP-Data program filterGraphic OnParameter/Pressure gradeMaintenance cut counterData Control / operation timeData Control / adjusting timeData Control / other timesData Control / aux. timeData Control / break timeAlpha keyboard On/Off Alpha keyboard, fast searchingfunctionPreset cut counterTime grade - infiniteAutotrim, put aside/aligningHolding down clamp in front of the knifeE - 13IntroductionPOLAR Cutting machines 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 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.CopyrightAll 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 - 14K1 - 1Machine LayoutFront side (Operating side)Rear sideK1 - 2PlanK1 - 3K1 - 4Transport and Installation of the MachineAfter Unloading•Remove all packing and wrapping material •Check machine and accessories for damages •Check for missing partsIn Case of ComplaintsImmediately send written note to:•Railway or shipping company •Insurance company•POLAR MOHR / AgencyPlace of InstallationThe location must meet the following requirements:•Vibration free location•Even concrete flooring, concrete property class: a min. of Bn 25•Observe carrying capacity!•Avoid possible accidents of operator by uneven flooring•Adhere to minimum distance from buildings or peripheral equip-ment (see plan).After the Installation of the Machine1.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 machine4.Final check according to check list5.Have handover signedHave the machine installed by POLAR service personnel, exclusively !The installation of the machine requires special skills which can be gua-ranteed only by especially trained experts of POLAR agencies.Arbitrary working on the machine may damage the machine itself or other material property of the user or cause accidents endangering life and limb of the staff.The machine must be unpacked, moved, transferred and installed byauthorized POLAR Service Technicians only. Dangers might arise from the machine itself or from its packing if it is unpacked, moved, transferred or installed with unsuitable devices.While the machine is unpacked, moved, transferred and installed, no other persons must be present in the range of the machine or its packing.The POLAR Service Technician must also take care that no unauthorized persons work at the machine, its packing or the installation equipment.Power Supply Type PlatesAK1 - 5K1 - 6Safety Relevant Machine Elements24581011151616163Safety Relevant Machine Elements1 Emergency-stop switch (main switch)2Light barrier (20-channel)Object detection capability: 25 mmMin. distance of light barrier:Total reaction time of system:Type 78336 mm< 121 msType 92345 mm< 125 msType 115372 mm< 140 msType 137372 mm< 140 msType 155392 mm< 150 msType 176392 mm< 150 ms3Safety latch for knife bar (mechanical lock against lowering of knife bar) 4Two-handed cutting release with simultaneity control and anti-repeat circuit5Electronics:- Failsafe control by multiple self-diagnostics- Machine self-diagnostics with error message6Guard to prevent reaching under the clamp bar7Rear-table guard, fixed or tiltable8Safety pressure for lowering the clamp by means of a pedal: Types 78, 92, 115, 137, 155:max. 300 NType 176:max. 500 N9Protection in case of con-rod fracture by shear bolt (predetermined breaking point)Max. breaking load Type 784,6 tType 92:7.6 tType 115:13 tType 137:15 tType 155/176:17 t10Safety catch for clamp return spring in case of spring fracture 11Guard of backgauge drive unit12Guard of main drive unit13Clutch-brake combination with braking efect in case of energy breakdown 14Menu-driven knife change per display15Complete table slit covering (in front of and behind the backgauge)16Warning plate for electrical operating area (high-voltage flash) This area may only be opened by authorized staff!Safety Auxiliary ToolsAngle for jogging the cutting materialWorking Area of Operating PersonnelWorking area is the complete front side (operating side) of the machine.K1 - 7Technical DataPermissible Environmental and Operating ConditionsOperate the machine in closed areas, exclusively!Air humidity:35% - 95% (non condensing)Ambient air temperature:+5°C - +40°CHydraulic DataHydraulic operating pressure:16 - 150 bars!The installation is designed for a maximum permissible pressure of 200 bars. Safety Precautions•Before starting any work at the machine - read safety section of manual!•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 material•Knife change may only be carried out by personnel especially trained for this purpose•Utmost care must be taken when handling the knife!!Always deposit or transport the knife in the knife case.•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 reachingunintentionally 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.•Observe the procedures described in case of malfunctions and the maintenance intervals indicated.Residual RiskIn spite of the safety measures provided by construction there remains a residu-al risk when operating the machine.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 general, if the necessary care is neglected.The parts especially affected are the upper extremities of the operating staff -especially their arms and hands.Special care must be taken when performing the knife change. It may only be carried out by personnel especially trained for this job!During knife change no other persons must enter the working area of the machi-ne (cuts)!Safety Inspection (only in Germany)Every 5 years safety inspetions of the machine must be carried out. This direc-tions is based on the Unfallverhütungsvorschrift Druck- und Papierverarbeitung (accident prevention rules in printing and paper processing) VBG 7i §40.Legal ProvisionsDocuments confirming that the machine complies with the binding regulations: The installation is fitted with a GS sign (proven safety) .The test was performed by the …Prüf- und Zertifizierungsstelle des Fachaus-schusses Druck- und Papierverarbeitung“ (Inspection and Certification Office of the Special Committee for Printing and Paper Processing), Rheinstraße 6-8, D-65189 Wiesbaden, according to the following test specification:•EN 292 T1•EN 292 T2•EN 294•EN 574•EN 60204•prEN1010K1 - 8。