Polar 115E, error message 654

hi @Long

Can i know why my Polar cutter doesn't show up the measurement and the scan reference points too doesn't show up the measurement. Please help me to fix this error! Thanks charlestan82@yahoo.com

 

Dear charlestan82,

please give me more information like how you do the scan reference point? which model of polar cutter did you have ?
assume you have scan it correctly it should show the measurement else please notice the action of the backgauge run upon scanning.
let say you started from front, the backgauge will run backward until the end limit and come forward and stop around middle.

Are there any other error messages shown on the screen?

 

Dear Long,

Thanks for the help! There were no current on the proximity sensor in the middle of the table. After changing the cable, the measurement appear! Now the scan reference points started showing measurement and machine back to normal.

Regard
Charles

 

Hello everybody,
Please anyone can help me?
I have the same problem error 654 but on polar 115 ED.
And if I go in auxiliary mode the backgauge does'nt advance only it can go backward.
my E-mail : donne2020@gmail.com
Thanks in advance.

 

Hi sir:

Please do this steps for that error
- Verify setting of frequency converte.
- Mechanical stiffness of backgauge drive, check table spindle.
- C014: with Lenze Motor=2, others=0. resp. see description of freq. Converter.
- Check / adjust backgauge drive motor with brake, brake is moving on small
measurements.
- Check and/or replace the backgauge drive motor with brake. (If the brake
is shaking when dealing with short cutting position, replace the brake)
- Frequency converter is defective (on machines with TML, check the display,
and compare with error list in frequency converter manual).
- Check / replace pulse generator
- Check cable routes / connections
- Check / replace SAP- board
- Check / replace CPxx- board
- Check proper connection of main terminals from backgauge motor
- Parting of cable to the limit switches in the clamp (S6, S218, S218b)
- Check fuse F8

- Check correct adjustment of S13 and switching cam
- Check correct grounding of backgauge motor

- Check tight fit of spindle extension
- Adjust 0V by means of potentiometer on board SAP.
- Verify smooth operation of slot cover band rolls.

- update XT with rear-table loading to V1.1.2-0 software or higher.
- Check plug no. 26 for Freq. Converter / SAP.
- Frequency converter setting, parameter step, try C016 with 8-20%.
(please, refer also to the current parameter list in the frequency converter
manual).
- Verify cable routes and connections (connectors 23/ 24 may be reversed).
- On machines with servo: check if toothed belt is too slack or to tense: Adjust
offset on SAP- board and/ or servo device.
- Check position B 341.
- After converting to Vector, there may be a contact malfunction on the I/O module

 

Hi,
Thank you for the reply and more instructions ,I did many of them.
I am going to try others .
Please what do you mean :
update XT with rear-table loading to V1.1.2-0 software or higher ?

 

You can try , some times the software Is coming corrupt.

Blessing

 

what to do if the software is corrupt ?
the chip can be replaced ?

 

Normally the Software is store in Flash-EPROMs in Cpu board with processor 186, you can download easy using the new software by using the
Card KC/or KC.

However you must measure 3.6 Vcd lithiums battery for Ram is the Voltage is low you must replace it. , where cutting programs is store, you have only 10 minutes for to do it.

 

I tested the voltage of the lithium battery and it is ok :3.6V

 

proceed with the other steps mentioned before +software

do this too.

1) Perform a visual inspection : look for loose and broken wires, improperly seated connectors, loose or broken wires
misset switch, missing jumpers. and so on.
Chech for obviously damaged component(components burned or discolore due to overheating);
Dust + dirt + tear +wear

2) Reseating Boards and components:
Edge connectors are a common souorce of problems. Power down the system and remove the PC boards. Examine the edge connector
for contamination and clean with contacts cleaner contacts. Reseat any loose components such as scoketed ICs) . Reseat the
boards and power up.

3) Power supply checks:
Check the power supply for missing voltages and voltages out of spec. A digital multimieter DMM can be necessary, as
voltage specifications are quite tight: logic supplies for example: must be within + 5% percent of 5Vdc. All the
multiple supplies and all must be checked.

4) Board swapping:
Board swapping involves the substitutiono of a known godd board for a suspect one.


5) Clock for CPU:
Check the frecuency with frequency counter or a DMM included frecuency counter( like Fluke DMM)


6)Reset CPU:
reset cpu see in the board Small switch S1

 

@CHOCK
Good afternoon, please advise.
Polar 115XT plus (M115-11)
2011y.
ser.8131105
115XT CP7 V2.0.2-0
boot: CPX V2.0.0

1) intermittent loading error when turning on the machine. blue screen with text:
"checksums verify error
download must be done
waiting for download"
after 2-3-10-20 shutdowns / pre-reboots with the button, the machine boots up normally and is ready for work

inspected all the boards, eliminated dirt / oxides / poor soldering. Checked cables and connectors.
it didn't fix the problem.
battery power 3.6v.
did not check the "bridge board" that connects the expansion boards to the cable connectors.

2)before checking and repairing the boards, the machine booted problematic but worked well.
after the repair, the back stop stopped working completely. in manual and automatic mode, there is no signal to the frequency converter.
Error 654

control LEDs of buttons / limit switches / protections show signals when manually on / off
backgauge motor, incremental screw position encoder, frequency converter, all of these components worked flawlessly before checking and repairing the boards

Please tell me which way to think. is it worth checking the "bridge board" with the removal from the machine or not?
I suspect error 654 caused a problem in SAP02 expansion board.

we will continue to look for the cause of the problems. I will write about the results of our work later.

Thanks a lot.

 

During an active backgauge run: if no or too few counting pulses are received fromthe signal transducer the above error message will be output.This is done whenever the actual speed of the backgauge falls below the nominalspeed by 1/8. On 78 ES, this error may be caused when the computer voltage isdropping too fast.
Remedy:
- Verify setting of frequency converte.- Mechanical stiffness of backgauge drive, check table spindle.- C014: with Lenze Motor=2, others=0. resp. see description of freq. Converter.- Check / adjust backgauge drive motor with brake, brake is moving on smallmeasurements.- Check and/or replace the backgauge drive motor with brake. (If the brakeis shaking when dealing with short cutting position, replace the brake)- Frequency converter is defective (on machines with TML, check the display,and compare with error list in frequency converter manual).- Check / replace pulse generator- Check cable routes / connections- Check / replace SAP- board- Check / replace CPxx- board- Check proper connection of main terminals from backgauge motor- Parting of cable to the limit switches in the clamp (S6, S218, S218b)- Check fuse F8- Current limitation G3 is active (POLAR 66)- Check correct adjustment of S13 and switching cam- Check correct grounding of backgauge motor- Install supporting rings for spindle (Polar 66)- Check tight fit of spindle extension- Adjust 0V by means of potentiometer on board SAP.- Verify smooth operation of slot cover band rolls.- On 78ES: install capacitor with cable connection (048320).- update XT with rear-table loading to V1.1.2-0 software or higher.- Check plug no. 26 for Freq. Converter / SAP.- Frequency converter setting, parameter step, try C016 with 8-20%.(please, refer also to the current parameter list in the frequency convertermanual).- Verify cable routes and connections (connectors 23/ 24 may be reversed).- On machines with servo: check if toothed belt is too slack or to tense: Adjustoffset on SAP- board and/ or servo device.- Check position B 341.- After converting to Vector, there may be a contact malfunction on the I/Omodul

 

The result of the repair.
after checking, cleaning and soldering the board: the machine boots stably.
violation of the breakage of the backgauge and errors 654 became superglue.
When checking the microcircuits, the panel case cracked, soldered with cyanoacrylate and installed the microcircuit.
Glue is an excellent insulator! )))
This happened to the problem with the machine described earlier.
The arrow indicates the leg of the microcircuit, which was insulated with glue.
Unfortunately, the photo is not infected, the car is at work.
This is how the story turned out for two days of downtime.

Many thanks to everyone who willingly or unwittingly helped with the repair!

 

God job sir