Polar 76EM Error code 82 MYSTERY

Hi all,

I've been diagnosing a Polar 76EM machine for a substational amount of time with error code 82 present.

What happens:
- the machine turns on, all cards light up and the screen shows 0
- I start the initial calibration, it goes backwards, forwards and lands in the middle (reference point)
- When it stops in the middle, I can hear the locking valve engage in the motor. It shortly shows the working screen and then goes to error and shows --82--.

This started happening during work in the middle of lunch, the machine wasn't turned off and when the worker came back it was in error 82.

What I've checked so far
- all voltages are correct
- all fuses are okay
- the locking valve is functioning properly (~20ohm)
- IAR - AR flat cable is good, I checked personally
- IAR - AR cards were tried in a different 100% working machine and they are functioning correctly in that machine, but not in this one.
- Checked the encoder on the moving rail, it works


What the explaination for this problem is:
error -82- cause by (During activating of locking valve -Y315 - the control transistor on card IAR does not function.)

The interesting thing is that the control transistor on IAR card works, it engages multiple times during calibration and also it engages when the error code 82 appears (goes to 0v on the valve, meaning locked because it's unlocked when it's powered)

I've seen people describe that this isn't a simple problem and most often it's not even connected to what the service manual says. I've been baffled by this issue and the fact that I can't figure it out, especially since it happens every time the machine starts up.

Any experience with this? I'd be very appreciative of any help.

Thanks!

 

Error 82 =During activation ofa hydraulic valve (for example when using the foot pedal) the electrical control system found a problem.
This may be caused by:
weak power supply 42V d.c.
Hydraulic valve Y315 broken or to low resistance
Board IAR broken
Board AR broken
flat cable from AR to IARbroken
First step would be a control ofthe power supply. Measure betvveen plug 403 pin 2 and plug 403
pin 5. You need at least 42 V d.c. Better is 45 V d.c.
Next thing would be to check the resistance ofthe coil ofhydraulic valve Y315. It should be
about 64 Ohm. You measure directly at the socket ofthe valve inside the hydraulic tank.
Next step would be to change parts. First IAR board, than the flat cable and at the end the board
AR.

 

Hi,

We traced the issue, so I will share the information if it helps someone else. Very thankful for synthology reply!

We removed the right panel where the oil is stored and the main pump, alongside the distribution block.

No oil will leak because it was designed to contain all the oil in the bottom so that the cover can be removed correctly.

Then we traced the cable from plug 6 on the SCU board (in the back of the machine, a big metal cover was removed and there was a PCB). The correct cables are SCU 6.8 and 6.9, meaning the pin 8 and 9 on the plug 6 on the SCU board (so people don't get confused).

On the schematic diagram, the Y315 valve solenoid is specified as ~78R (78 ohm +-10% I guess, so even 68-70 ohm is okay). Measuring this solenoid we measured 25 ohm, meaning that instead of the original 48V/78R= 0.615A now it is 48V/25R=1.92A which is too much for the traces on the IAR card, making the transistor very hot and causing large voltage drops. When the machine senses that there's too much current draw and there is a large voltage drop, it cuts everything. It displays error 82 ("Error 82 =During activation of a hydraulic valve (for example when using the foot pedal) the electrical control system found a problem."). This makes sense when turning on the machine because it can't activate this valve, displays an error, and protects the user so bad things can't happen (for example, the clamp stays up but the blade moves down, this can't happen, and is very dangerous).

Is this valve the same as on the POLAR 115 EMC? Part number 017081 (Aliexpress 457 EUR)? They look the same in pictures, and I can't find anywhere the part number for 76EM. Can anyone confirm?

 

Hi sir:

Test the folowing for that error # 82:
Check connection IAR - AR (flatwire
harness)
Exchange card IAR + AR.

Do not waste time....!

 

IAR + AR cards fine, tested in other machine. Flat is fine, tested.

The problem is solenoid, it has 25 ohm resistance instead of ~70ohm. I'm looking for a replacement or part number, any ideas?

 

Give the parts number+ serial number+ delivery County x calculate Freight+ your email please.

Blessings

 

Polar 76EM Y315 valve 027984

 

This valve is Y315, it has too low resistance and needs replacing.

 

We have rewound quite a few over the years but make sure you replace all o rings as it’s the hydraulic oil running out of the plug breaks down the resins on the coil wire.

 

Hi Sir: Will be a good idea to make a new wound, i see is Reheating, NOT burning, but is like close to burn. or Replace it by a new ONE........!!!!

2) However, after repair the Y 315 in the Hydraulic system, and put new oil, YOU must be sure, to bleeding the complete system
for Air, otherwise, you will see another problem. o.k?? Replace O- rings .

Let me know.