Service manual

CNC-Control MAXI 5 Premium

starting from version 1.16
Cross-Cut Systems

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Phone +49 (0)7371 / 500-0 Fax +49 (0)7371 / 500-111 en B 736.08/2
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Table of contents

13 Service ................................................................................................................................3

13.1 General ..........................................................................................................................3

13.2 Service parameters .......................................................................................................4
13.2.1 S-Operating modes.............................................................................................................4
13.2.2 S-Machine ............................................................................................................................6
13.2.3 S-Measuring station ...........................................................................................................9
13.2.4 Length accuracy (Option) ................................................................................................13
13.2.5 Axis Parameters................................................................................................................14

13.3 Inputs/Outputs .............................................................................................................17

13.3.1 Display inputs ...................................................................................................................17
13.3.2 Display and switch outputs ............................................................................................20
13.3.3 Runcontrol.........................................................................................................................22
13.3.4 Counter ..............................................................................................................................24

13.4 Allocations ...................................................................................................................25

13.4.1 Matrix cutting list ..............................................................................................................25
13.4.2 Matrix - Statistic ................................................................................................................26
13.4.3 Matrix Optimisation parameter........................................................................................26

13.5 Optimisation parameters .............................................................................................28

13.5.1 Optimizing mode...............................................................................................................28
13.5.2 Minqual. finger-joint Quopt..............................................................................................28
13.5.3 Number of combinations .................................................................................................28
13.5.4 Min. FJ length....................................................................................................................28
13.5.5 Max. FJ length ...................................................................................................................29

13.6 Sorting Stations ............................................................................................................29

13.7 Language change-over................................................................................................30
13.8 Set and test axes.........................................................................................................31
13.8.1 Set speed ...........................................................................................................................32
13.8.2 Positioning error ...............................................................................................................32

13.9 Width measuring (Option) ............................................................................................32

13.9.1 Calibrating the width-measuring.....................................................................................32

13.10 Standard parameters ..................................................................................................33

13.11 Adjusting clock............................................................................................................34

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13 Service

13.1 General
The operation of the machine is subdivided into several levels:
Level 0: User level
Level 1: Service 1, password-protected, change to service settings possible
The level you are in is displayed in the login-field. You can log in or out by clicking on the login-field.

Picture 13-1: Login - Field

You should have the most exact knowledge of the data to be changed and its consequences. In case of
doubt consult your dealer or the manufacturer before any changes.

Important!
It is advisable to print out all parameters before changing. In the case of an incorrect
setting, the printed out data can be very helpful for restoring the original status.

The Service-Menu is divided into several points:

Picture 13-2

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13.2 Service parameters
The service parameters are password-protected. If a parameter is selected, a password query follows.
After entering the password and confirming with <Yes> or with <Enter>, the parameter editor window
opens and the parameter can be changed. The limiting values of the parameter concerned and the
current setting are displayed in the editor window.

13.2.1 S-Operating modes Service Service parameters S-Operating

modes

Operating modes – settings have switching functions that switch program functions or machine functions
on or off.

Picture 13-3

13.2.1.1 0=mm / 1=Inch (201)

With this operating mode one can determine if entries in the cutting lists and displaying cutting lists or
statistics are done in the metric system (in millimetres) or in the American system (inches).

Entries in inches each have a maximum of 3 places before and after the decimal point.
13.2.1.2 Width measurement on/off (264)
When a width-measuring device (optional) is connected, it can be switched on and off here.
The optical width measuring device incorporated in the measuring station serves to measure the width of
the workpieces processed. The cutting list can be changed over by means of the measured width. The
widths can be divided up into different groups.
When using the optional 'packing box' software ("panel program") the overall width of the boxes required
can be calculated as well.
The statistics register the area of the workpieces processed.

13.2.1.3 Finger jointing trim cut on/off (268)

End trimming of finger-joint lengths If a finger-joint length is produced at the board end, an end cut is
made with this operating mode.

No trimming of finger-joint lengths The end cut is not carried out with this setting.

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13.2.1.4 1st roller 1 up/down on/off (270)
Two photocells are mounted in the cross-cut station (each consisting of a transmitter and a receiver). The
first photocell (viewed in the direction of feed) is used to control the solenoid valve of the first top roller.
The pressure of the first top roller is controlled in this operating mode. Because of the high feed speed
this top roller is not actually cycled. Only the upper cylinder space is supplied with compressed air so long
as the light beam of the photoelectric barrier is interrupted.

13.2.1.5 Clamping hood on/off (271)

Clamping device ON The clamping device operates in this mode, but only at the board end and with
fixed or finger-joint lengths shorter than 230 mm.
Clamping device OFF This operating mode must be set if no clamping device is fitted. In this way the
installation attempts to cut a length longer than 230 mm at the board end. If this
is not possible (e.g. because there is only a short section available at the board
end), then all the remainder is cut up for firewood.

13.2.1.6 Sorter on/off (272)

Sorting equipment ON Only with connected sorting equipment.
Sorting equipment OFF In this operating mode the entry of the sorting station in the cutting lists is
omitted.

13.2.1.7 Code (Inkjet printer) on / off (273)

This operating mode is only relevant in combination with a special software’s special functions.
These are for example:
Ink-jet printer

13.2.1.8 Panel program on/off (274)

The 'packing box' program ("panel program") only works in conjunction with a width measuring unit. If
switched on, the cutting list contains an extra column with the heading "Control". In this column you can
select one of the following functions of the columns "Programmed number of pieces" + "Cut pieces":
1: Programmed number of pieces + Cut pieces
2: Width required to be cut + Width cut (the width is determined by the width measuring unit)
3: Area required to be cut + Area cut (area = length of piece cut x width measured))

13.2.1.9 Speed control on/off (275)

Speed control ON With this operating mode intervals can be produced between two length
sections on the subsequent sorting belt. In this way the machine independently
controls the feed speed. (See also Chapter “Min. Intervals” on sorting belt).
Speed control OFF Operating mode not in use. The normal feed stop program can now be used
(see also Chapter “Feed stop time”).

13.2.1.10 Top roller control system on/off (276)

The top roller control system operating mode ON allows different wood thicknesses to be sawn one
directly after the other.

13.2.1.11 Autom. setting reference (277)

Please do not modify the setting of this operating mode. Usually it is switched off.
If this operating mode is switched on, an automatic reference is set. It is only necessary for an
unfavourable pitch of gear.

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13.2.2 S-Machine Service Service parameters S-Machine

Picture 13-4

13.2.2.1 Width of cut (203)

The width of the saw cut is entered here in millimetres.
The setting can also be used for correcting constant (length-independent) length inaccuracies.

13.2.2.2 Distance PH Æ sawblade (207)

The distance from the saw blade to the photocell in the cross-cut station for wood start detection is set
here. This is so to speak the reference point from board start to saw position.
If the trim cut is too short (long) and / or the cut takes place before (after) the crayon lines (quality
optimisation OFF) then this value should be increased (decreased).
The decisive criterion for the setting of this value should therefore be the accuracy of the preset leading
end trim cut. Note that the resulting trim cut is always shorter by the width of cut of the saw blade. For
example, with a set trim cut of 30 mm and a saw blade thickness of 5 mm the actual trim cut is only 25
mm long.
The photocell located closer to the saw position / saw blade is responsible for the PH -> Saw distance.
The other photocell is used for driving the solenoid valve of the first top roller.

13.2.2.3 Restart after WARNING (213)

Use this function to set the length of time in seconds that the cross-cut installation is stopped after a
warning occurs.
If the time is set to 0, the function is switched off. In this case you have to restart the machine manually.
In the case of a FATAL ERROR the operation stops.

Caution!
After expiry of the set time, the installation starts again automatically!!!

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13.2.2.4 Dist. from BE (board end) ‘til clamping hood (214)
If the residual length of the board is shorter than the amount set here, the clamping device is active and
holds the board firm during cutting.
If 6,500 mm is entered, the clamping device is active for every cut.

13.2.2.5 Wait until clamping hood is down (215)

The number of seconds that the saw lift is delayed by with the clamping device (optional) switched on can
be specified here. This ensures that the clamping device is securely restraining the item to be cut at the
time of sawing.

13.2.2.6 Wait before blowing (217)

Here the waiting time is entered until the waste is blown out. This time goes by he cutting time. It must be
set big enough for the cutting operation being finished when the waste is blown out.

13.2.2.7 Motor pulses per revolution (285)

Here the number of pulses per motor revolution can be entered. This parameter is set in the software of
the servo regulator and taken over here. Please modify this value only if a service technician of the
manufacturer ask you to do it.

13.2.2.8 Gearbox servosaw fraction numerator (286)

Different kind of gears are used for different machine types which use his software. Please enter here the
numerator of the gearbox servosaw multiplication. Example: I=5:1 Æ Entry 5

13.2.2.9 Gearbox servosaw fraction dominator (286)

Different kind of gears are used for different machine types which use his software. Please enter here the
dominator of the gearbox servosaw multiplication. Example: I=5:1 Æ Entry 1

13.2.2.10 Pulse length sort belt (302)

The sorting equipment has a pulse encoder for measuring wood length (see also sorting measurement
tolerance) and eject position. The pulse encoder is usually a proximity switch, which detects the teeth /
pulses of a chain pinion on the drive of the first sorting belt and notifies the CNC control. The tooth pitch
of the chain wheel corresponds to the pulse length.

The pulse length can be determined as follows:

• Turn the sorting belt by hand until the corresponding LED on the E2 input interface just
comes on;
• mark the conveyor belt and the conveyor body;
• now turn the conveyor belt again until the associated LED switches on again;
• the distance between the marking on the conveyor belt and the conveyor body is the
corresponding pulse length,
• repeat this process three times to confirm the test result.

Among other things, the ejection accuracy of the sorting stations as well as any sort alarm that occurs
depend on a correctly set sort alarm.

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13.2.2.11 Distance saw -> PH sorting equipment (303)
The distance between the cross-cut station and the photocell on the sorting equipment is entered here.

This function can be used to sort cross-cut lengths which are longer than the distance between the cross-
cut station and the sorting station photocell.

13.2.2.12 Feed speed sorting belt (304)

The sorting equipment belt speed is entered here in m/s. This time is important when using the Speed
Control operating mode (see Chapter “Speed control”).

13.2.2.13 Min. gap on sorting belt (305)

The minimum theoretical gap between two length sections on the sorting belt are entered here in 0.01m.
Only active if Speed control operating mode is on.

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 S-Measuring
13.2.3 S-Measuring station Service Service parameters Station

Picture 13-5

13.2.3.1 Offset scanner 1 (220)

This is the distance between the switching point of the wood start / wood end photocell (PH) in the
measuring station and the switching point of the upper luminescent scanner (Lumi #1). The luminescent
scanner must never be installed so that it switches before the photocell, otherwise crayon lines could be
detected before the wood has been detected. The distance should preferably be nearly zero.
An incorrect setting is apparent when the cuts are made slightly but constantly close to the chalk lines
(with quality optimisation switched off). The connection with the distance photocell -> saw is complex,
since although an incorrect setting there causes cutting near the crayon lines, but at the same time the
trim cut is correspondingly too short / long.

Setting rule:
The trim cut must first of all be set to "0".
A board is marked with a straight, thin but obvious line at exactly 100 mm from the start. Ensure that this
chalk line is marked as near at right angles as possible to the board edge.
Go to the "Saw” operating mode. The cross-cut feed system starts as long as no error has been was
detected in the self-test.
Place the marked board in front of the measuring station and have it measured by the measuring system.
Ensure that the measuring station is correctly set to the appropriate wood thickness.
Immediately after measurement carefully intercept the board between the measuring station and the
cross-cut station and remove it.
The distance between the board start and the crayon line (first measured length) can be read off on
screen at upper left. It must correspond approximately to the marked length of 100 mm. Inaccuracies of 2
millimetres are within the measurement tolerance range and do not have to be corrected.

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Large deviations are corrected as follows:
• If the measured length is too great by x millimetres, then “Offset luminescent scanner 1” is
increased by x millimetres.
• If the measured length is too small by x millimetres, then “Offset luminescent scanner 1” is
decreased by x millimetres.

This test can be repeated several times in order to establish a mean measurement for the offset

13.2.3.2 Offset scanner 2 (221)

This parameter is only provided and effective if the installation is equipped with a second luminescent
scanner for lateral quality marking. The method of operation and the setting is as for “Offset luminescent
scanner 1“.

13.2.3.3 Switch 2nd meas. wheel (222)

This is the distance in mm between the photocell (PH) for wood start / wood end detection and the
changeover point from the first to the second measuring roller. This value is only effective if the
measuring station is fitted with two overhead measuring rollers. Normally the factory setting is not to be
changed.

Caution!
This value is never to be set to less than the mechanical distance between the
photocell in the measuring station and the second overhead measuring roller.

If your cross-cut installation is not equipped with two overhead rollers, the following settings apply:

Model 14 MKL 0 mm
Model 14 E / KE 14 mm
Model 11 MKL 11 mm
Model 11 E / KE 11 mm

13.2.3.4 Beginning of width measurement (224)

The width-measuring system (optional) measures the board widths some 50 times per second. The
measuring is done regardless of whether there is wood in the measuring station or not. Somehow the
Maxi CNC control must be informed of the time at which and after which distance the board width must
be read in by the CNC control. This is done with the distance of the photocell in the measuring station to
the width-measuring device.

Important!
Do not set this distance too large or the wood width of very short input lengths cannot
be perfectly detected.

13.2.3.5 Mode of width measurement (225)

The workpiece width is measured by an optical width measuring unit built into the measuring station. The
cutting list can be changed over by means of the measured width. The widths can be divided up into 16
different groups.

The optional box software can also be used to calculate the overall width.
The statistics ascertain the area of the workpieces processed.
Width measuring mode of operation:
Two triangulation measuring heads that measure the distance to the wood using a
laser beam. These triangulation measuring heads each send an analog voltage to the
control. The width of the wood is determined from these in the CNC controller.

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Selecting the width-measuring unit in the software:
The control has to know which width-measuring unit is installed in order to interpret the ingoing data
correctly. For this, the operating mode in question is entered in the parameter menu at the “Width
measuring mode” point.
The following operating modes 5 to 11 are required with an AD/DA converter card 24-428.32
Operating mode 5: two triangulation measuring heads with a range of max. 160 mm
Operating mode 6: two triangulation measuring heads with a range of max. 180 mm
Operating mode 7: one triangulation measuring head with a range of 180 mm and one triangu-
lation measuring head with a range of 300 mm
Operating mode 8: two triangulation measuring heads with a range of max. 300 mm
Operating mode 10: two measuring heads Dyna Vision with a range of 200 mm
Operating mode 11: one measuring head Dyna Vision with a range of 200 mm and one measuring
head Dyna Vision with a range of 300 mm
Operating mode 12: two measuring heads Wenglor with a range of max. 300 mm
For calibrating the width-measuring unit please look at chapter “width measurement”.

Danger!
Never look directly into the laser beam. It is so bright that eye-damage could occur.

13.2.3.6 Offset of width measurement (226)

This value is automatically provided by the program during width measuring calibration and must not be
altered.

13.2.3.7 Split optimising loss (240)

The split optimising loss mode is only enabled when quality optimisation is switched off.

This operating mode is used to distribute the resultant optimisation remainder and has three different
settings:
Split optimising loss mode 0 In this operating mode the optimisation remainder is moved to the
board end.
Split optimising loss mode 1 In this operating mode half the resultant optimisation remainder is
distributed on both sides. The distribution only happens if the
optimisation remainder is smaller than the set minimum finger-joint
length. If the remainder is greater than the minimum finger-joint
length the corresponding finger-joint length is cut.
Split optimising loss mode 2 In this operating mode the optimisation remainder is distributed as
in split optimising loss mode 1 and any resultant finger-joint lengths
are integrated.

13.2.3.8 Mode of marking (241)

These operating modes are only available if “Change via marking code” operating mode is switched on.

13.2.3.8.1 Line recognition mode 1

In this operating mode only one luminescent scanner for defect recognition and grade changeover is
effective. The following distances must be maintained to distinguish the markings for defects or grades:
Grade changeover: minimum 10 mm, maximum 30 mm
Defect marking minimum 40 mm (only applies with line code changeover switched on)
The board start is also evaluated as a crayon line.

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13.2.3.8.2 Line recognition mode 2
The laterally fitted luminescent scanner is activated in this operating mode.
The different grade zones are marked on the top face of the board. The marks applied to the edge of the
board indicate the grade number concerned.

Without grade marks the grade of the preceding grade zone is retained. A grade change must be
designated by a lateral mark within a grade zone. Lateral grade marks can be in any place at any
distance.
The board start is also evaluated as a crayon line.

13.2.3.8.3 Line recognition mode 3

The laterally fitted luminescent scanner is activated in this operating mode.
The different grade zones are also marked on the top of the board. Each crayon line marks the start of a
new grade zone. Lateral grade marks must be made within these grade zones. They can be in any place
at any distance.
Without grade marks the grade zone is coordinated to grade 1.
The board start is also evaluated as a crayon line.

13.2.3.9 Max. admissible waste (242)

If there is a remainder after optimisation that exceeds the maximum permissible waste, then a
combination is made up that leaves a remainder of the minimum finger jointing length in size.
Example: overall infeed length = 1200 mm
shortest programmed cut length = 1000 mm
leading end = trailing end trim cut = 20 mm

1st. maximum permissible waste = 5000 mm (normal case)

→1000 mm (programmed length) + 5 mm (saw cut) + 155 mm (waste)
2nd. permissible waste = 50 mm
→1160 mm (finger jointing length)
If the value for the max. per. waste is decreased, then the production of finger jointing lengths increases
and the waste is reduced.

13.2.3.10 1 Chalk line Æ Quality (245) ... 9 Chalk lines Æ Quality (253)
These settings only take effect if the line code changeover is switched on.
Here you can allocate the number of crayon lines for a specific grade. The simplest way is to allocate 4
lines to grade 4, for example.

13.2.3.11 File name for board storage (258)

To generate a file of the cut workpieces, e.g. for simulation purposes, enter a file name for parameter
"258 File name for timber stack". If you do not want to have the cut workpieces stored in a file, set this
parameter to "0".

Important!
The file will be continuously extended by new data until the parameter "258 File name for
timber stack" is set to "0". After having generated a specific file, reset the parameter to
"0" to prevent the file/memory from getting unnecessarily large.

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13.2.4 Length accuracy (Option)

Service Service parameters Length accuracy

Your CNC cross-cut system can be equipped with an optional 'outfeed length identication' (length
detection photocells for an increased accuracy). Please note that the outfeed length identification only
works with a smooth saw cut. Chip-out would adversely affect the result.
In addition, the following parameters must have been entered correctly:

Illustration 13-6

13.2.4.1 Tolerance length accuracy (360)

This tolerance serves to determine the activity zone of the outfeed length accuracy.

13.2.4.2 Dist. RS1 length accuracy (361, 362, 363, 364)

Enter the distance between saw blade and reflex sensor for the outfeed length identification. The reflex
sensors are located on the outfeed belt conveyor.
The values measured by the outfeed length identification are displayed during cutting:

Illustration 13-7

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13.2.5 Axis Parameters

Service Serviceparameters Servo motors

Danger!
Setting / changing these parameters requires a fundamental knowledge of control
engineering as well as the complete feed system. Changes should only be made by
service engineers or under the instructions of the manufacturer. Incorrect settings may
represent a risk to life and limb.
The parameter menu for each axis is constructed in the same way. Which of the three menus you are in
is displayed on the screen.

Picture 13-8

13.2.5.1 Acceleration (101, 121) / Deceleration (102,122, 142)

The acceleration / deceleration of the feed drive in m/sec2 is set with this parameter. In normal cases this
value is set to the maximum expected feed system acceleration / deceleration. There is usually no point
in having a higher setting since the feed will not accelerate faster in any case. A reduction of the
acceleration can mean an improved length accuracy in certain circumstances.

13.2.5.2 Max. speed forward (103,123, 143) / Max. speed reverse (104,124, 144)
This is the maximum feed speed that can be travelled for positioning. Here also the factory-set values are
the maximum values obtainable. A reduction of the speeds can make sense in order to adjust the feed
system of the cross-cut installation to a slower processing cycle of a preceding machine.

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13.2.5.3 KS (105, 125, 145)
This is the control circuit amplification factor. For commissioning or for defining the axis parameters the
factor should be set to the value “1”. In saw operation the value should be set to “4”.

Important!
If the value for “ks” is set to zero, then correct control behaviour or setting the control
parameter is no longer possible. Set this value to “1” at least

13.2.5.4 KV (106, 126, 146)

This value depends on the regulator standardization. Please take the value to be set from the parameter
list supplied.

13.2.5.5 Offset (107, 127, 147)

This parameter can be used to eliminate a possible occurrence of feed axis drift behaviour.

13.2.5.6 Speed to ref. point (108, 128, 148)

The value entered here specifies the speed at which the reference run is carried out.

13.2.5.7 Ref. Pos. (109, 129, 149)

Distance that the drive travels on to the final wait position (reference position) after approaching the
reference point (initiator).

13.2.5.8 Allowable deviation (110, 130, 150)

The axis concerned must reach its target within this deviation to continue the automatic sequence,
otherwise it would stop.

13.2.5.9 Linear acceleration (112, 132, 152)

This parameter is only of importance in conjunction with positioning mode 2 (see parameters
115/135/155). It determines from which speed the acceleration on sine² positioning should be linear.

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13.2.5.10 Mode of positioning 1=WR 2=sin2 3=WWP (115, 135, 155)
The different positioning modes indicate the course of acceleration:

1 = WRS:
This positioning mode is particularly useful on partial optimisation on the model "KE" CNC cross-cut
systems.

Acceleration

4
v

3
Speed

0
0 0,1 0,2 0,3 0,4

Illustration 13-9

2= sin2

This positioning mode is used on model "MKL" CNC cross-cut systems. The size of the radius of the
rounded section of the curve is influenced by the "linear acceleration from" parameter.

Acceleration

4
v

3
Speed

0
0 0,1 0,2 0,3 0,4

Illustration 13-10

3=WWP

In this positioning mode it accelerates to the final speed as fast as possible, without taking account of any
lag time.

Acceleration
Caution!
In this positioning mode the components are
5
exposed to extreme stress due to the high
4
acceleration. To avoid damage being done to them, the
positioning mode WWP must only be used on the express
Speed

2 instructions of the manufacturer and only for the servo

1 cutting stroke axis (option).
0
0 0,1 0,2 0,3 0,4

Illustration 13-11

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13.3 Inputs/Outputs Service Inputs/Outputs

13.3.1 Display inputs

Picture 13-12

The inputs can be displayed via the “Service, Inputs/Outputs“ menu.

To be able to check the input signals easily, there is an LED located on each sensor and at each input on
the input interface card. They are located at the rear in the CNC control cabinet.

This menu can also be used to check if the software has also detected the input signal.

Switch status 0 No voltage at input (no signal, no tick)

Switch status 1 Input is switched, i.e. 24V DC applied (signal there, tick before the designation)

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13.3.1.1 Inputs E1

Nr. Name Description

1 Photocell measuring station Input signal of the photocell in the measuring station, consisting of
a transmitter and receiver for wood start and wood end
recognition.
2 Photocell measuring station Used for checking the function of the photocell. In this case the
alarm switch status 1 must be available (= 24V DC) or an error message
is output.
3 PH at infeed chain Input signal of the photocell on the supply conveyor.
4 PH at pressure roller Input signal of the photocell on the pressure roller.
5 Scanner 1 Input signal of the board top face luminescent scanner for mark
recognition.
6 Scanner 1 alarm Used for checking the function of the luminescent scanner. In this
case the switch status 1 must be available (= 24V DC) or an error
message is output.
7 Scanner 2 Input signal of the side-mounted luminescent scanner (optional)
for grade changeover.
8 Scanner 2 alarm Used for checking the function of the luminescent scanner. In this
case the switch status 1 must be available (= 24V DC) or an error
message is output.
9 … free input
10 … free input
11 … free input
st
12 Photocell at 1 . roller Input signal of the photocell in the cross-cut station, consisting of
a transmitter and receiver for controlling the first top roller.
13 Photocell at 1st. roller alarm Used for checking the function of the photocell. In this case the
switch status 1 must be available (= 24V DC) or an error message
is output.
14 Photocell wood start in the Input signal of the photocell in the cross-cut station, consisting of
machine a transmitter and receiver for detecting the wood start and wood
end.
15 Photocell wood start in the Used for checking the function of the photocell. In this case the
machine alarm switch status 1 must be available (= 24V DC) or an error message
is output.
16 Proximity switch saw bottom Input signal of the proximity switch for checking the lower position
of the saw rocker.

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13.3.1.2 Inputs E2

Nr. Name Description

1 ... free input
2 ... free input
3 Photocell sorting 1 input signal of the photocell on the sorting belt for wood
recognition.
4 ... free input
5 machine released Enable signal to upstream machines or handling equipment
6 Proximity sorting belt Input signal of the proximity switch installed at the end of the (first)
sorting belt near the chain drive. The pulses of this proximity
switch are used for the length and distance measurement of the
workpieces to be sorted.
7 ... free input
8 ... free input
9 Pressure switch (air) Input signal of the pressure switch on the service unit inside the
cross-cut station. If the air pressure is too low (less than 3.5 bar)
an error message is output.
10 ... free input
11 ... free input
12 Motor protection switch Input signal of all the installation’s motor protecting switches. As
soon as one of these protecting switches is switched off, an error
message is output.
13 ... free input
14 ... free input
15 Servodrive alarm Used for checking the function of the servo-controller for the feed
drive. In this case the switch status 1 must be available (= 24V
DC) or an error message is output.
16 Overtemperature Checking the temperature of the switch cabinet

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13.3.2 Display and switch outputs
Service Inputs/Outputs

Picture 13-13

For simply checking the output signals, an LED is located on the corresponding output of the output
interface cards (marked red). These cards are located at the rear in the CNC control cabinet.
Switch status 0 (output signal not activated, no tick) no voltage applied at output
Switch status 1(output signal activated, tick before the designation) output is switched, i.e. 24V DC
applied
The outputs can be switched directly in these menus by operating the appropriate function number. If you
select an output signal, the login prompt follows. After entering the password you can activate the output
concerned.

Caution!
Machine functions are triggered when outputs are switched on! For this reason, the
outputs are only to be switched by the machine operator when the machine is stopped.

If the corresponding LED on the interface card does not react when outputs are switched, then there is
either a fault in the computer or on the interface card or a malfunction in the electrical circuit (incl. relays
on the output interface card).

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13.3.2.1 1. MV 1st roller
This output signal switches the solenoid valve of the first top roller in the cross-cut station

13.3.2.2 MV Roller before saw

This output signal switches the solenoid valve of the last top roller before the saw blade.

13.3.2.3 MV Roller behind saw

This output signal switches the solenoid valve of the first upper roller after the saw blade.

13.3.2.4 MV air jet waste

This output signal switches the solenoid valve of the air-jet blower for removing the waste in the area of
the saw blade.

13.3.2.5 MV Blower width measurement

This output signal switches the solenoid valve of the blower on the width-measuring unit type B (optional).

13.3.2.6 MV Clamping hood

This output signal switches the solenoid valve of the clamping device in the cross-cut station (optional).

13.3.2.7 MV pressure roller belt

This switch signal switches the pressure roller solenoid valve on the conveyor belt.

13.3.2.8 Infeed chain

This output signal switches the infeed chain and thus the mechanization before the machine.

13.3.2.9 ...
Non-assigned output

13.3.2.10 MV Sorting station 1- 32

These output signals are transmitted to the sorting station solenoid valve (optional) via the A3 interface
card.
MV Sorting station 1 This output signal switches the solenoid valve for sorting station 1 of the sorting
unit.
In the same way, the following outputs 2 to 32 switch the associated solenoid valve of the sorting stations
in question.

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13.3.3 Run control Service Inputs/Outputs

Picture 13-14

The top four switch positions are inputs, the remaining four are outputs. A tick in the box in front of the
designation of the input/output concerned means switch position 1; if there is no tick, the switch position
is 0.

13.3.3.1 Run Control inputs

All “Run-Control“ inputs are located on the RC interface card (marked white) in the CNC control cabinet.
These inputs are function-checked during the self-test.

1 RC-test Switch status 1 means that the green key has been pressed. The
installation is ready to operate.
2 AUS-test Switch status 1 means that the white key is currently not being pressed or
held down.
3 Emergency Stop -test Switch status 0 means that the Emergency Stop circuit and the door
interlock circuit were closed by pressing the green key.
4 Machine started Switch status 1 means that the Run-Control R99 relay has picked up.

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13.3.3.2 Run Control Outputs
Outputs 1 to 5 control the semiconductor relays on the RC output interface card.
Caution!
Machine functions are triggered when outputs are switched! For this reason, the
outputs are only to be switched by the machine operator when the machine is stopped.

5 RC Relay Switch status must always change (“trigger”) between 0

and 1 after the green key is pressed. The Run-Control
R98 relay is functioning.
6 Saw lift control This output signal switches the solenoid valve for the saw
lift.
Comment:
Although the saw lifting valve has a nominal voltage of 24V DC, the valve is controlled by a voltage of
30V DC in order to guarantee quick opening.
7 Reset servo drive This output signal cancels malfunctions in the servo
drive.
8 ... Non-assigned output

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13.3.4 Counter Service Inputs/Outputs

Picture 13-15

The events are counted here:

Counter 1 Machine feed
Counter 2 Measuring station
Counter 3 Measuring station
Counter 4 Servo saw lift (depending on machine design)

The following impulses are counted here:

Combicard Counter 1 feed axis machine
Combicard Counter 2 measuring rollers/measuring tape (depending on
machine design)
Combicard Counter 3 measuring rollers/ free (depending on machine design)
Combicard Counter 4 Servo saw lift (depending on machine design)
Combicard Counter 5, 6 free

DIGIO Counter 1 encoder/approach switch of the sorting system

DIGIO Counter 2, 3 free

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13.4 Allocations Service Allocations

13.4.1 Matrix cutting list

Picture 13-16

The allocations of cutting lists to the different wood widths and wood grades is determined here.

The allocation is completely free, so that the same cutting list can appear several times in the table.

It can be specified in each line (width group) for each grade, which cutting list should be used for
optimisation.

In the case of a connected width-measuring unit (optional), a width range can be programmed for each of
the 20 width groups. The group changeover then follows automatically. The particular width range (e.g.
“26 – 32“) must be specified in millimetres.

If there is no width-measuring unit connected to the cross-cut installation, the group changeover must be
done manually (cf. Chapter “Sawing“ in the operator manual B736.08/1).

Select the allocation or width range to be changed with the pin on the touch screen and change the value
via the keyboard. When you subsequently click on another allocation field or go to another field with the
keyboard arrow keys, the change is accepted but not saved! So that the changes also take effect after a
restart, they must be saved (<Save> button in the command bar).
An error message appears in the case of invalid values.
Other functions:
Reload: If no alteration has been stored, the 'reload' function allows to reopen the original matrix.
Complete column: The value entered is taken over for the whole column.

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Caution width ranges:

• Altering a width range in any allocation table automatically entails a simultaneous alteration in all
other allocation tables.
• In principle, the width ranges can be programmed without spaces, with spaces or overlapping.
• If there are spaces between the individual ranges and a width is measured that falls in a space,
then an error message is output. A width range of 10 mm – 350 mm can be programmed in the
width group 20 to prevent this error message and a suitably adjusted cutting list assigned. In this
way all pieces of wood that fall into a so-called “width gap” are processed further in the width
group 20.
• Measurement errors of ± 1mm must be taken into account by the width-measuring unit.
• If overlapping ranges are programmed, then the first group from the top is used where the
measured width falls in the programmed width range.
• The width ranges are to be programmed so that the smaller width is on the left of the hyphen and
the larger width is on the right.
• If width ranges (groups) are to be locked, the you can set the figure on the right of the hyphen
smaller than the number to the left of the hyphen.

13.4.2 Matrix - Statistics

The allocations of statistics to the different wood widths and wood grades is determined here. A
maximum of 20 different statistics are available.
The allocation is completely free, so that the same statistic can occur several times in the table.
It can be specified in each line (width group) for each grade in which statistic the optimisation results
should be recorded.
In the case of a connected width-measuring unit (optional), a width range can be programmed for each of
the 20 width groups. The group changeover then follows automatically. The particular width range (e.g.
“26 – 32“) must be specified in millimetres.
If there is no width-measuring unit connected to the cross-cut installation, the group changeover must be
done manually (cf. Chapter “Sawing“ in the operator manual B 736.08/1).
Select the allocation or width range to be changed with the pin on the touch screen and change the value
via the keyboard. When you subsequently click on another allocation field or go to another field with the
keyboard arrow keys, the change is accepted but not saved! So that the changes also take effect after a
restart, they must be saved (<Save> button in the command bar). An error message appears in the case
of invalid values.

13.4.3 Matrix Optimisation parameter

The allocations of the optimisation parameter settings to the various wood widths and wood grades are
established here.
The allocation is completely free, so that the same optimisation parameter setting can appear several
times in the table.
It can be specified in each line (width group) for each grade, which optimisation parameter setting should
be used for optimisation.
In the case of a connected width-measuring unit (optional), a width range can be programmed for each of
the 20 width groups. The group changeover then follows automatically. The particular width range (e.g.
“26 – 32“) must be specified in millimetres.
If there is no width-measuring unit connected to the cross-cut installation, the group changeover must be
done manually (cf. Chapter “Sawing“ in the operator manual B 736.08/1).

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Select the allocation or width range to be changed with the pin on the touch screen and change the value
via the keyboard. When you subsequently click on another allocation field or go to another field with the
keyboard arrow keys, the change is accepted but not saved! So that the changes also take effect after a
restart, they must be saved (<Save> button in the command bar). An error message appears in the case
of invalid values.

Caution width ranges:

• Altering a width range in any allocation table automatically entails a simultaneous alteration in all
other allocation tables.

• In principle, the width ranges can be programmed without spaces, with spaces or overlapping.

• If there are spaces between the individual ranges and a width is measured that falls in a space,
then an error message is output. A width range of 10 mm – 350 mm can be programmed in the
width group 20 to prevent this error message and a suitably adjusted cutting list assigned. In this
way all pieces of wood that fall into a so-called “width gap” are processed further in the width
group 20.

• Measurement errors of ± 1mm must be taken into account by the width-measuring unit.

• If overlapping ranges are programmed, then the first group from the top is used where the
measured width falls in the programmed width range.

• The width ranges are to be programmed so that the smaller width is on the left of the hyphen and
the larger width is on the right.

• If width ranges (groups) are to be locked, then you can set the figure on the right of the hyphen
smaller than the number to the left of the hyphen.

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13.5 Optimisation parameters Service Optimisation parameter

Picture 13-17

13.5.1 Optimizing mode

The choice between partial and full optimisation can be made here:
Partial optimisation =1
Full optimisation =2

13.5.2 Minqual. finger-joint Quopt.

If an optimisation remainder is to be processed for finger-jointing, this board section must have at least
the quality set here. Lower qualities are classified as “Waste”.

13.5.3 Number of combinations

The computer carries out the maximum number of optimisation calculations set here. The best of the
results calculated are then cut.

13.5.4 Min. FJ length

This is the smallest reusable remaining length (normally for finger-jointing). This measurement is set to
the minimum length value which your finger-jointer can still process.
If no finger-joint lengths are to be produced, then this parameter is to be set greater than the smallest
programmed fixed length. In this case only fixed lengths are produced since fixed lengths are basically
preferable to finger-joint lengths.
If the maximum finger-joint length is exceeded, the piece is divided up so that at least one piece of the
minimum finger-joint length is produced.
Example: min. finger-joint length = 500 mm
max. finger-joint length = 1500 mm

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Based on the crayon marks on the wood and the cutting lists or parameter settings, a finger-joint piece of
1760 mm overall results. In accordance with the above limits for the finger-joint lengths two finger-joint
pieces of 500 mm and 1260 mm are produced.

13.5.5 Max. FJ length

It is specified here how long a maximum finger-joint length can be. Should it happen that a finger-joint
length is divided up so that this value is undershot, then on the other hand at least the minimum finger-
joint length is produced

Important!
The maximum finger-joint length must be set to be at least twice as long as the minimum
finger-joint length.

13.6 Sorting Stations Service Sorting Stations

Picture 13-18

The ejection cylinder of a specific sorting station is located at a specific distance from the photocell at the
start of the sorting installation. The photocell represents so to speak the reference point for the sorting
stations / ejector.

To keep the sorting system as flexible as possible, the distances between the individual ejectors and the
photocell can be set with the help of this menu. If you mount an ejector in another position, the distance
set here must be adjusted.

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There are three different methods (modes) to eject the cut lengths into a sorting station:
Mode 1 leading edges flush
Mode 2 centred
Mode 3 trailing edges flush
As a rule the ejectors are programmed so that the wood is ejected centred from the sorting belt.
The figures behind the word "Sorting station" refer to the particular relay of the output interface card in the
CNC control.

13.7 Language change-over Service Language change-over

Picture 13-19

Select the desired language from the pull-down menu. Activate the selected language with <Save>.

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13.8 Set and test axes
Service Axis setting
Danger!
Setting / changing these parameters requires a fundamental knowledge of control
engineering as well as the complete feed system. Changes should only be made by
service engineers or under the instructions of the manufacturer. Incorrect settings may
represent a risk to life and limb.
The axis setting is carried out on the one hand by defining the axis parameter (see Chapter “Service
Parameters“) and on the other hand by adjusting the regulator. The “Axis Adjustment” service function is
used for this:

Set speed

Lag error

Picture 13-20

By means of this display you can check if the axis parameters and the regulator are set correctly. To do
this, proceed as follows:
• Start the saw by pressing the white key.
• Select the requested axis number.
• Enter a value, e.g. 1000 into the “rel.position set value“ field.
Important!
The value entered is to be seen as a distance. The axis will be moved forward or
backward by this value. The moving direction can be changed by the <+/-> button
(+ to move forwards, - to move backwards).

By actuating the <Start> button the infeed belt conveyor will now move 1000 mm from the set position.
During this movement the diagram shows the set speed (red) and the lag error (yellow). The fields below
the diagram show the current values issued by the machine.

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Except for small deflections when approaching and braking the lag error (yellow) must be about 0 (see
Picture 13-20).

13.8.1 Set speed

The progress of the set speed results from the set axis parameters (acceleration, deceleration, max.
speed, infeed speed).

13.8.2 Lag error

The lag error is a mathematical relationship between the theoretical position (cmd) and the actual drive
position (actual position). The computer calculates the distance that the drive has to cover in a specific
unit of time. The difference between the theoretical specification and the practical distance is known as
the lag error.
Adjust the regulator and parameters so that the lag error is about 0 (see Picture 13-20). A small
deflection can always be detected during acceleration and deceleration.

13.9 Width measurement (Option) Service Width measuring

The optical width measuring device incorporated in the measuring station serves to measure the width of
the workpieces processed. The cutting list can be changed by means of the measured width. The widths
can be divided up into different groups.
When using the optional 'packing box' software ("panel program") the overall width of the boxes required
can be calculated as well. The statistics register the area of the workpieces processed.

Picture 13-21

13.9.1 Calibrating the width-measuring unit

After the correct operating mode has been selected, a planed piece of wood is placed between the
measuring heads. The measured width is displayed. Then enter the actual width into the “Manually
measured width” field and store it (<Save> button). This calibrates the width measuring unit. The correct
width should then be displayed in the “Automatically meas. width” line.
If “Automatically meas. width 0 mm” is displayed, then one of the measuring heads is not in measuring
range. The DC voltage of the two measuring heads is displayed at the top of the screen. These can be
checked with a DC voltmeter.

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 Important!
During the measurement the analog voltage must move between the limits of - 8 V
DC und + 8 V DC for Operating mode 5 ... 8, for Operating mode 10 ... 12 the analog
voltage must move between the limits of 0 V DC und 10 V DC or the scanner falls
outside the measuring range and measurement is switched off.

The measuring accuracy depends on many factors:

- The measurement of smooth wood surfaces is more accurate than that of rough wood.
- The measuring unit must be installed at right-angles to the wood.
- The measuring heads and mirror must be clean. No water spray, condensation etc.

Danger!
Never look directly into the laser beam. It is so bright that eye-damage could occur.

13.10 Standard parameters Service Standard parameters

Load default parameters

Load default allocations

Load default optiparameters

Load default sorting stations

Write buffer to disk

Data storage to floppy/USB

Data storage from floppy/USB

Save standard parameters

Picture 13-22

The factory-set parameters, allocations, optimisation parameters and sorting stations are stored in this
menu and can be loaded by pressing the appropriate button. Before the data is opened, there is a control
query (see Picture 13-22), that you must acknowledge with <OK>. It is also possible to cancel the
procedure if the function is selected accidentally.

Important!
If you load the default data, the current settings are overwritten by the default settings.
If the default parameters are loaded, then not only are the machine, waste, measuring
station/sorting and mechanization parameters overwritten, but also the service
parameters.

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The "Write buffer to disk" function serves to activate an already loaded software update.
The "Data storage to floppy/USB" and "Data storage from floppy/USB" functions allow the parameter
settings, allocations, optimization parameters and sorting stations to be stored to or from a disk or USB
stick (due to the differing formats, not every, but most of the commercially available USB sticks can be
used).
By using the "Save standard parameters" function the current parameter settings can be stored as
default parameters.

13.11 Adjusting clock Service Adjusting clock

Using this function you can set date and time of the control computer. Press the button <Save> to take
over and store the settings. If there is a network connection you can take over the browser time.

Picture 13-23

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