TRE 145-185 (1995) 29-2-99 Service Descarga Derecho Ingles PDF

TRE95e1_ / 29.02.
1999
Transomat
E145
E185
(Versions Drupa 95)
Imprint: File: TRE95e1_.pdf / first edition: 26.06.1995

Use: all Transomat E145, E185 after Drupa95
Writer: Klaus Meiselbach
remark: see latest changes
pages: 48+1
1 Accompanying documentation
29.02.1999 / TRE95e1_
table of contents
Survey of the different types of Transomat machines ........................................... 3

View from the front....................................................................................................4
View from the rear ..................................................................................................... 5
Control System ..........................................................................................................6

Structure .................................................................................................................... 6
Power Supply ........................................................................................................... 7
Description of Function Cards ................................................................................. 7

Plug-in Card „Positioning Computer“ ..................................................................... 7
Plug-in Card „Transomat Interface“ ........................................................................8
Safety Installations....................................................................................................9
Pneumatic System .................................................................................................. 11

Valve Unit ................................................................................................................. 11
Pneumatic Diagram E145 / E 185 ........................................................................... 13
Frequency Converter (FU) Lenze 8200 .................................................................. 14

Information on the operation and adjustment of converter 8200 ....................... 14
Overwriting of the parameter set by factory calibration ..................................... 15
Hydraulic System .................................................................................................... 17

Setting instructions for control card EVR2A1P .................................................... 18
Hydraulic diagram ................................................................................................... 20
Ready for operation ................................................................................................ 21
Pallet lifting .............................................................................................................. 22
Pallet lowering ......................................................................................................... 23
Machine Functions .................................................................................................. 24

Switching-on ............................................................................................................ 24
Emergency-stop loop .............................................................................................. 24
Ready for operation ................................................................................................ 25
Manual Pallet Movements ....................................................................................... 26
Lower pallet manually (from table height) ............................................................ 26
Lift pallet - (pallet is at bottom position) ............................................................... 27
Advance pallet (from initial position) .................................................................... 28
Return pallet (from front position) ......................................................................... 29
Size Adjustment ...................................................................................................... 30
Automatic Operation ............................................................................................... 31
High pile ................................................................................................................... 31
Small pile ................................................................................................................. 37
Latest changes ........................................................................................................ 49
Accompanying documentation 2
TRE95e1_ / 29.02.1999
Survey of the different types of Transomat machines
There are basically two main types of machines. The loading units serve to pick the cutting material up
and convey it to the cutting machine, while the unloading units unload the material on pallets.
Below, the various types of Transomat machines are listed:
1. Type designation
TR 1 E R 185- 6
Transomat
Position with respect to cutting machine
Type: B (loading unit) E (unloading unit)
Side of machine where Transomat is positioned (left/right)
Pile height, max.
Offset size
Options: GRF = gripper

CHP = chip
HA = semi-automatic (standard on E145)
VA = fully automatic (option on E145, standard on E185)
2. Technical Data
E145-4 E145-6 E185-6 E185-7S
Size 80x120 105x145 105x145 122x164

Height of ream, max. 16,5 cm 16,5 cm 16,5 cm 16,5 cm
Pile height, max. 145 cm 145 cm 185 cm 185 cm
Carrying capacity, max. 200 Kg 200 Kg 250 Kg 250 KG
Weight, net 1060 Kg 1145 Kg 1600 Kg 1700 Kg
Power required 2,3 kW 2,3 kW 2,3 kW 2,3 kW
Accompanying documentation
29.02.1999 / TRE95e1_
B82 M8 B1 B9 B10 EVO B7
SVO
B12
B11
B29
SVU EVU
View from the front

M2 ESO
4
ESU
(82a)
B82b
B78a M2 Y11
B78 A6
A2 A1 B4 B3 A5
B7 B11 Y1-Y10 Q25 M8 M6
SSO
View from the rear

5
SSU (B82a)
B82
B3
B4
145 B27 B6
A5
185 B8
TRE95e1_ /
B5
145 B8
185 B27
M1 Y6 Y3 B71 Y11 M2
29.02.1999
29.02.1999 / TRE95e1_
Control System
Structure
The control system is accommodated on a switchboaard located in the tower of the Transomat unit. It
is divided into a control unit and a logic unit. The control unit consists of a transformer, protective
switch, contactors, relays and evaluators for the safety light barriers as well as the safety bars.
The logic unit is a motherboard fitted with plug-in cards TRN and PS5 as a power supply, positioning
computer and TRI cards as logic operations. Besides, there is a control box at the sledge which
contains frequency converters (FU) and relays for controlling the motorized movements.
X20
V1 V1 V24 1
2 1.
K17
TC-02 3 15
K19 TRN PS 5 AR TRI a TRI c 1
2 2.
K18 3 15
K20 F2 F5 F3
1
2 22.
K57 3 15
K59 V30
K58
K60 V36
1
X0 2 21.
3 15
V40
3 2 1 3 2 1 3 2 1 3 2 1
V46
V25
X50 1
15 15 15 15
F4 F7 F9 2 4.
3 12
9. 51. 41. 42. 52.
X40 F1 F6 F8
X30
K02 K03 A01 A81 A67 K5 K6 K7
11 20 11 20
Test Test
K1M A35 frei A40 frei
F2M F1M LSU LSU
1 10 1 10
X10 X13 X11 X12 X14 X2 X3 X4 X5 X9
K75
switchboard Transomat E
TRE95e1_ / 29.02.1999
Power Supply
The transformer supplies the following secondary voltages:

1. 25Va.c. for emergency stop loop and power supply 25 Va.c.
2. 27Va.c. for power supply + 25Va.c (via rectifier V1)
3. 25Va.c. for cards TRN and PS-5
With emergency-stop loop intact the following secondary voltages are supplied:
1. 24Va.c. (for A35, A40, K1M) protected by F3
Measuring point: X1. 24a.c.
2. 25Vd.c. (for relays K75, K7, K6, magnetic valve YH3 and all pneumatic valves) fused by F5
Measuring point: X1. +25
3. 24V from TRN card (for all inputs TC02) fused by F2 and fuse on card TRN
Measuring point: X1. +24
4. 5 Vd.c. from card PS5 (for computer AR) fused F2 and on card PS5
Measuring points: Card PS 5
Description of Function Cards
Plug-in Card „Positioning Computer“

The positioning computer (AR) is the „heart“ of the control
system. It contains the machine program filed in an
EPROM. The card makes logic operations of the various TC 02
signals from operating elements, limit switches, sensors
and light barriers controlling the manual or automatic
sequence of functions of the Transomat corresponding to
TRE HY A
the respective software.
The label on the EPROM indicates the software version
Polar AR V1.0
present (e.g. TRE HY A V1.0).
When replacing this card it must be made sure that the
version valid for this particular machine is
installed.
Curent software version: TRI "A" TRI "C"

Semi automatic = TRE HY V1.2 Inputs Inputs
full automatic = TRE HY A V 1.4
Positioning Computer
TRI "A" TRI "C"

Outputs Outputs
29.02.1999 / TRE95e1_
Plug-in Card „Transomat Interface“
Plug-in Card „Transomat Interface“ (TRI-24) is a

universal input and output circuit which supplies
the computer with the information entered TC 02
(operating elements, proximity switches, limit S1 S2 S3
switches, light barriers) and transforms the
commands output by the computer by activating
the corresponding elements (valves, contactors,
relays). The Transomat units use two TRI cards
which are of identical design. They merely differ Polar TRI
in the settings of the three BCD switches S1 - S3.
(delays, operation)
The functions of these cards differ in their module
location (TRI „A“, TRI „C“).
Please observe the following basic adjustments of the BCD switches for the semi-automatic (HA) and
fully automatic version(VA):
Card Switch Semi-autom. Fully-autom. Meaning
TRI A S1 8 4 Gauge time

TRI A S2 4 4 Gripper time
TRI A S3 4 4 Post-lowering time
TRI C S1 0 0 Lift gauges prematurely

TRI C S2 1 1 Aligning ON/OFF
TRI C S3 0 4 Afterrun of gauge
The „gauge time“ is meant as a steadying time in various situations:

1. Allows the pneumatic cylinders enough time to move the gauges horizontally.
2. Allows the counter gauge enough time to form a proper contact for the piling down.
3. Delimits the removal of the piling gauge from the material loaded, before said gauge is lifted.
The „gripper time“ has two effects:

1. Preset time for the pneumatic system when the pile is aligned.
2. Allows the grippers (option) enough time to grip the material securely and to open.
The „post-lowering time“ is effective after the pile height has been detected by light barrier A1 and
until the hydraulic system is shut off.
The function „lift gauges prematurely“ has two states:

1. „0“ = The piling gauge first moves away horizontally from the inserted material and
is then lifted.
2. „1“ = The piling gauge is lifted without having moved away from the material
horizontally.
The function „Aligning ON/OFF“ has two states:

1. „0“ = The aligning movement is switched off.
2. „1“ = The aligning movement ahead of the switch B27 is switched on.
The function „Afterrun of gauge“ becomes active in the fully automatic type after the paper edge has
been detected by LS A6 and until the movement of the gauge is stopped.
TRE95e1_ / 29.02.1999
Safety Installations
1. Relay A01 as a make combination with positively driven contacts.
2. As with the latest version of the Transomat machines we use safety contact bars to secure the pallet
movements. These safety bars are contact systems which respond to very light touches already. Two
groups of bars can be divided. Safety bar B78 (only E145) and B78a (vertical direction) are fastened
under the side edge of the pallet and monitored by evaluator A67. Safety bar assembly (horizontal direction)
B 82a (only E185) and B 82b is attached at the rear edge of the pallet and B 82 at the front side of the
holding-down clamp and is scanned by evaluator A 81. Both evaluators are also accommodated on the
switchboard. After being contacted the safety bars also disconnect the control system (emergency-stop
loop). B 78 with A 67 by NC contact of relay K 75 is only alert during the lowering movement of the
pallet.
These safety bars include two contact materials which do not have any transition in uncontacted condition.
Between the evaluators and the terminating resistor one or more of these safety bars are arranged. The
evaluator electronic system is calibrated to this resistance value of 1,2 k ohms. A deviation to approx. 700
ohms is recognized by the device as a „contact“ or a short-line fault whereas a resistance change of
approx. 1,9 k ohms is evaluated as an interruption of the safety bar or a parting of a cable. In both cases
the evaluation circuit cuts off two safety relays per device. The NO contacts of the two evaluators A 67
and A 81 are integrated in the emergency-stop loop of the make combination.
3. The emergency-stop loop employs also a pneumatic pressure switch (B71) which prevents the operation
of the Transomat machine in the case of a pressure drop or if no compressed air is available at all. The
turn-off value of the pressure switch should be approx. 4.8 bars.
4. Light barrier A2 (pile edge) serves as a safety cut-off during the manual pallet advance movement, but
does not switch the installation off.
5. The safety light barriers monitor the danger zone between the piling and the counter gauge as well as
the area behind the counter gauge. Safety light barriers A31, A32, A33 and A34 form a safety curtain
between the piling and the counter gauge. Light barriers A36, A37, A38 and A39 are arranged in the
counter gauge. The two evaluators are accommodated on the switchboard in the tower. Interruption of a
single beam causes the complete control system to be switched off (emergency-stop loop).
The safety light barriers assembly consists of the following components:
1. two evaluators A 35, A 40
2. four transmitters A 31, A 33, A 36, A 38
3. four receivers A 32, A 34, A 37, A 39
Once the mains voltage of the Transomat has been
switched on the two evaluators A 35 and A 40 are
supplied with 24 V a.c. The supply voltage is supplied
at the secondary side of transformer T 1 to terminals 1 +
2 of the evaluators.
The evaluators are secured against short circuits by a
fuse (100 mA/250 V). To replace the fuse, the housing Test
of the evaluator must be opened.
LED 1= yellow
LED 2 = green
= selftest
= ready for operation
A35 frei
LED 3 = red = interruption LSU
29.02.1999 / TRE95e1_
Selftest performed after supply voltage has been switched on
A selftest is performed with the evaluator and the transmitters and receivers connected. At output 17 (
T ) of evaluator A 35 and A 40 a high signal is briefly applied. This causes the connected transmitters
to be switched off and the inputss 13/14 and 15/16 coming from the transmitters will be inverted during
the test. The yellow and red LED at the evaluator are lit during the selftest. Once the test has been
passed the red LED is extinguished and the green LED lights up. The light barrier is ready for operation
and the contacts at connection 3 + 4 of the evaluators, which are part of the emergency-stop loop, will
be closed.
6. Transomat units with fully automatic size adjustments are fitted with two safety functions for their
automatic runs. If no material is detected between the gauges during a piling process the cycle will be
briefly interrupted, but continued after that.
If LS A6 detects material for a very short moment (<1sec.) this will be interpreted as an error and the
automatic cycle will be aborted.
TRE95e1_ / 29.02.1999
Pneumatic System
All movements except pallet movement are carried out with compressed air and pneumatic cylinders. The
machine can be supplied by central systems or by compressors delivered by the machine manufacturer.
The amount of air provided must be a min. 20l/min. (145) and 25 l/min. (185E). The pressure should be
between 6 and 8 bars.
The required operating pressure of 6 bars can be adjusted at the conditioning unit located at the tower.
As soon as the system falls short of the minimum pressure (4.8 bars) the emergency-stop function will be
released by the pressure switch. This ensures operating safety, since an insufficient air pressure would
impair the functioning of the Transomat unit.
The following cylinders and valves are employed in the control system of machine types E:
Valve Cylinder Function
Y1 Z1 Free lifting
Y2 Z2 Aligning gauge return (only semi-automatic)
Y3 Z2 Aligning gauge advance (only semi-automatic)
Y 4a Z4 Counter gauge lower
Y 4b Z4 Counter gauge lift
Y5 Z5 Counter gauge advance
Y6 Z6 Lower pallet tips
Y7a Z7 Aligning gauge lift
Y7b Z7 Aligning gauge lower
Y8 Z8 Aligning gauge advance
Y9 Z9 Holding-down clamp lower
Y10 Z10 Grippers closed (option)
Valve Unit
The movements are activated from a valve unit. The modules are assembled depending upon the type of
machine and equipment used. When the control voltage is switched off the functions can be checked by
activating the valve functions by means of control pushbuttons. Every plug is fitted with an LED which
indicates its activation.
Y7b Y4a
(Y10) Y9 Y8 Y7a Y6 Y5 Y4b (Y3) (Y2) Y1
29.02.1999 / TRE95e1_
The cylinder connections or the exhaust-air outlets of the magnetic valves are fitted with exhaust -air
throttles which can be used for adjusting the travel speed of the pistons. The cylinder heads are also
furnished with adjustable limit position dampers. This makes it possible to adjust the mechanical run
briskly, but „smoothly“.
Attention! Exhaust-air throttles or limit position dampers that are turned off may block the cylinder
movement!
When repair work or adjustments are being performed at the pneumatic installation the following points
must be observed:
1.) Constant operating pressure of 6 bars.
2.) Discharge condensate (in newer installations automatically performed)
3.) Mechanical smoothness of movable parts
6.) Are exhaust-air throttles and limit position dampers correctly adjusted?
7.) Are the switches for limit position reached?
8.) Are the hoses laid correctly?
9.) Are the screwed joints tight?
B12
B11
semy-automatic
Pneumatic Diagram E145 / E 185
1.5 bar Free lifting

Counter gauge aligning gauge
Aligning gauge
Aligning gauge
Grippers
clamp Aligning gauge
Counter gauge
(semi-automatic)
Paletttips
13
Y7b Y4a
Y10 Y5 Y7a Y6 Y8 Y4b Y9 Y2 Y3 Y1

TRE95e1_ /
6 bar
29.02.1999
29.02.1999 / TRE95e1_
Frequency Converter (FU) Lenze 8200
Transomat machines are fitted two different frequency converters. Lenze FU

V1 V2
The pallet drive units have 0.75-kW converters. A 0.375 kW converter Display
is used for size adjustment. The devices are precalibrated by the 1 STP
SH PRG
producer, precision adjustment is made during machine final RUN
1
acceptance in the plant.
62 20
7 28
8 E1
In case a device must be replaced at the customer‘s: 9

K11
E2
E3
K12 E4
1. jumper position at FU must be corrected (FU for pallet movement K14 39
has jumper position 4-3)

2. preset values must be checked and performed again, if necessary.
This requires the use of a detachable programming unit. This
device with the respective operating instructions can be purchased W
V
U
from the Polar spare parts department, id. no. 229709 . It must be -UG
+UG
available as an auxiliary tool at every Polar agency. N

L1
PE
Information on the operation and adjustment of converter 8200
The frequency converters of series 8200 are presently used in POLAR machines for different functions.
The current fields of application are the backgauge drive units in the cutting machines and the control of
movmentes in peripheral equipments.
Two LEDs on the device indicate the current mode when the machine is switched on:
LED green red Indication

active active Power on / restart lockout
flashes off Converter locked
active off Converter enabled
off flashes (1s) Error
off flashes (0.4s) Undervoltage
off off Programming mode
Programming unit „8201BB“ can be clipped onto the frequency converter.
The programming unit is fitted with the following pushbuttons:
STP Locking of frequency converter

PRG Changeover from operating level to code level and vice versa
SH Changeover from code level to parameter level and vice versa
Attention! Parameter set 1 (PAR1) is used, exclusively.
PRG+SH Store adjusting values
/ Pageing on code and parameter levels
RUN Enabling of operation
To preadjust and check the units contained in the machines it is possible to:
make nominal value adjustment by jumpers, if necessary
transfer factory adjustment into the current parameter set,
check or modify current parameter sets,
display operating data while automatic backgauge is active.
TRE95e1_ / 29.02.1999
Overwriting of the parameter set by factory calibration
The frequency converters 8200 supplied through POLAR have been factory adjusted. The presetting
serves to provide a faster adaptation of the frequency converter to the needs of POLAR Transomat
machines. The factory adjustment can be taken over into the first parameter set (PAR1) in the following
way:
1. Press key „PRG“ of programming unit (switches from operating level to code level).
2. Use key „ “ or „ “ to select step C002.
3. Key „SH“ switches over to the display of the current value (parameter level).
4. Use any of keys „ “ or „ “ to select value 1.
5. Press keys „SH“ and „PRG“ simultaneously. Changeover is acknowledged by „SET 1“.
6. Press „RUN“ key.
Attention!
After factory adjustment has been adopted, steps C001, C007, C010, C011, C012, C013, C015 C037
and C038 must be adapted to the requirements of the POLAR Transomat machines. (see
„Modification of current set of parameters“)
Modification of current set of parameters

The current set of parameters (PAR1) can be checked and modified manually.
1. Clip programming unit „8201BB“ onto frequency converter
2. Press key „STP“.
3. Use key „PRG“ to switch over to code level.
4. Use key „ “ or „ “ to preselect the desired parameter set.
5. Press key „SH“ (Changeover to parameter level)
6. Modify the current value (parameter) by means of key „ “ or „ “
7. The new parameter is stored by pressing keys „SH“ and „PRG“, simultaneously.
Indication „SET 1“ acknowledges the procedure.
8. Return to operating level by pressing key „PRG“.
Depending on the field of application the frequency converters require different preadjustments for working
correctly. On POLAR Transomat machines the following parameter sets are used:
CODE Benennung Palette HA Palette VA Palette VA (V1.4) Lineal
C001 Type of operation 0 0 0 0

C007 Terminal configuration 0 0 0 0
C010 Min. rotating field frequency 30 Hz 30 Hz 30 Hz 20 Hz
C011 Max. rotating field frequency 90 Hz 90 Hz 90 Hz 70 Hz
C012 Acceleration time 2 2 2 1
C013 Deceleration time 0,5 0,5 0,5 0,2
C015 U/F relation 50 Hz* 50 Hz* 50 hz* 50 Hz*
C037 Slow speed 30 Hz 30 Hz 15 Hz 25 Hz
C038 Fast speed 90 Hz 90 Hz 90 Hz 50 Hz
*For motors other than 230V/50 Hz the adjusting values for the U/F relation suitable for the respective
motor voltage must be inquired.
29.02.1999 / TRE95e1_
Error messages issued by the frequency converter (displayed on programming unit „8201BB“)
LU = Mains voltage too low, check mains voltage, correct transformer adaptation , if necessary.
OVd.c. Mains voltage too high, check mains voltage, correct transformer adaptation , if necessary.
OC1 Short circuit at motor output
OC2 Earth fault at motor output
OC3 to OC6 Overloading of devices, adjustment of parameter sets, check motor and cabling
OH Excessive heat sink temperature, check ambient temperature, clean heat sink
PR to PR2 Error in data transfer, use other programming unit, check parameter sets to and from
programming unit
ramp time must be shorter
than travel time between
limit switches slow and stop, recp.
acceleration time deceleration time

CO12 C013
"fast" terminal 8
C038 5V
range of
potentiometer
"slow"
C037
0V
start by stop by
controller enabling controller locking
terminal 28 = 15 V terminal 28 = 0V
B29 B12
fully automatic
TRE95e1_ / 29.02.1999
Hydraulic System
The upward and downward movements of the

Transomat pallet are controlled hydraulically. YH6
M1 proportionalal valve
The hydraulic system is composed of: emergency
control card for proportional valves lowering valve
hydraulic cylinder with pipe shearing pin
hydraulic power pack
proportional lifting and lowering block.
YH3
The Transomat control system requests a lowering valve
hydraulic upward or downward movement of the
pallet depending upon the manual or automatic pressure
motions. For this purpose, a lowering valve and a balance
proportional valve are employed. The proportio- control valve
nal valve together with an automatically regulating
pressure balance control the speed of upward and shuttle valve
downward movements. The lowering valve seals manometer
the tank line (leakage only) when no descending connection
is carried out. The shuttle valve is at resting
position on the lowering movement. When the
hydraulic pump generates an oil pressure, the
lifting function is switched over. These valves are
accommodated in the hydraulic control block.
max. pressure valve
By an emergency lowering valve the Transomat 140 bar
pallet can be lowered even without any power
supply.
Control card EVR2A1P for proportional valve
A control card controls the functioning of the proportional valve. The control power of the proportional
valve can be measured at sockets B (at the front of the control card) as a direct voltage.
The control card is inserted into a support at the tower. When mounting the card, care must be taken that
the lockings snap in correctly!
When substituting a control card for the Hoerbiger hydraulic power pack the jumper positions must always
be checked and re-adjusted if necessary. When using the control card in POLAR-Transomat machines
the following jumper settings must be adhered to:
Jumper Condition J8
1 Pos. 1
2 Pos. 1 J7
3 Pos. 2
4 open J9
J1 J2 J3 J4 J5 J6
5 open
6 open
7 open
8 Pos. 1
T2,5 A
9 closed
29.02.1999 / TRE95e1_
The card has the following LED and potentiometers (starting from the top):
Designation Indication
Festwert 1
LED green Ready for functioning contin.

Festwert 2
Poti fixed setpoint 1 (setting of bias voltage)
LED yellow fixed setpoint 1 (presetress) contin. Festwert 3
Poti fixed setpoint 2 (setting low-speed)
LED yellow fixed setpoint 2 (low-speed) when a slow movement Festwert 4
is requested
Poti fixed setpoint 3 (setting fast speed)
LED yellow fixed setpoint 3 (fast speed) when a fast movement is A B
Rampenfahrt
requested
A B
Setting instructions for control card EVR2A1P
To operate the Transomat correctly, the control card must be adapted to the Istwert
hydraulic power pack and the situation present in the corresponding Transomat Sollwert
machine. B
A
Adjustment of fixed setpoints
Fixed setpoint 1:
First, adjust „fixed setpoint 1“ (Bias voltage for proportional valve). By a voltage
permanently supplied to the valve a buzzing noise can be noticed. LED „fixed setpoint 1“ is the only one
active. Fixed setpoint 1 is in the range of 200mVd.c. to 300mVd.c.
For the adjustment proceed in the following way. Secure the operating area of the Transomat. Connect
voltmeter to terminals B . Then activate magnetic valve YH3 permanently (e.g. bridge K75 9-10). Turn
potentiometer for fixed setpoint 1 so that the measured voltage is reduced. After some time, the pallet will
start a slow downward movement . Note the voltage measured at that moment (e.g. 143mVd.c.) The
potentiometer for fixed setpoint 1 is then turned to the opposite direction. The voltage to be measured
rises. After everal turns of the poti the pallet starts again to move downward. The voltage measured at that
moment must also be noted down (e.g. 337mV). When the two values are compared there is a mean
value of 240mV. This value is adjusted at the poti for fixed setpoint 1.
Remove the jumper for YH3.
Fixed setpoint 2:
Connect voltmeter to measuring socket B.
Move pallet to table height and disconnect coil from K6 and K7.
Besides, bridge contacts 11 and 14 on relay K6.
Light-emitting diodes „fixed setpoint 1“ and „fixed setpoint 2“ are lighting up.
When Down button is held in!
The pallet is moving without ramp generation, constantly at slow speed.
The time to travel the distance between table level and final cut-off should be approx. 18 seconds.
A readjustment for changing the lowering speed is executed at potentiometer „fixed setpoint 2“.
Nominal value: 370mVd.c. - 420mVd.c.
Connect the coil of K7 again after the adjustment has been made.
Fixed setpoint 3:
Adjust „fixed setpoint 3“ (fast speed) bridge contact K6 - 11 with contact K7 - 14.
Leave the coil of relay K6 disconnected.
The pallet is moving without ramp generation, constantly at high speed. When Down button is held in!
Move Transomat pallet to table height.
LEDs „fixed setpoint 1“ and „fixed setpoint 3“ light up.
The time to travel the distance between table level and final cut-off should be approx. 8 seconds.
Nominal value: 490mVd.c. - 530mVd.c.
A readjustment for changing the lowering speed is executed at potentiometer „fixed setpoint 3“.
TRE95e1_ / 29.02.1999
Fixed setpoint 4 is not used for the control of Transomat E units.

Adjustment of ramp
The ramps can be adjusted by two turning knobs located at the front side of the control card. The adjustment
by the upper turning knob affects noticeably the start of the movement when lifting and lowering the pallet;
a hard start (in jerks) or a smooth start of the movement.
The setting of the lower turning knob affects

noticeably the end of the movement when lifting
and lowering the pallet; a hard (in jerks) or a
smooth stop of the movement.
At first, both turning knobs are turned ccw until

the slides in the potentiometer housings are at the
very right. This is the minimum ramp.
After that, move Transomat pallet upward (above
table height). If the movement starts in jerks the
upper adjusting screw must be turned clockwise.
The ramp is extended. The movement is started
more smoothly.
Upward movements and readjustments should be
repeated several times.
After that, move Transomat pallet downward. If

the slowdown during speed change (A5) take place
with a jerk the lower adjusting screw must be
turned clockwise. The ramp is extended. The
movement is finished more smoothly.
Downward movements and readjustments should
be repeated several times.
ramp time by ramp time by

upper adjustment srew lower adjustment screw
"fast"
fixed setpoint 3
(Festwert 3)
"slow"
fixed setpoint 2
(Festwert 2)
29.02.1999 / TRE95e1_
Hydraulic diagram
cylinder
pipe burst protection
emergency lowering valve
YH3 lowering valve
YH6
proportional valve
(volume regulation)
pressure balance
control valve
(pressure regulation)
shuttle valve
manometer connection
motor with hydraulic pump
max. pressure
limitation 140 bar
hydraulic tank
TRE95e1_ / 29.02.1999
Ready for operation
cylinder
YH3 lowering valve
Fixed setting 1
YH6
proportional valve
(volume regulation)
pressure balance control

valve
shuttle valve
motor with
hydraulic pump
pressure limitation
max. 140 bar
hydraulic tank
29.02.1999 / TRE95e1_
Pallet lifting
cylinder
YH3 lowering valve
fixed setting 2 or 3
YH6
proportional valve
(volume regulation)

valve
(prssure regulation)
shuttle valve
motor with
hydaulic pump
pressure limitation
max. 140 bar
hydraulic tank
TRE95e1_ / 29.02.1999
Pallet lowering
cylinder
YH3 lowering valve
fixed setting 2 or 3
YH6
proportional valve
(volume regulation)

valve
shuttle valve
manometer connestion
motor wtih
hydraulic pump
pressure limitation
max 140 bar
hydraulic tank
29.02.1999 / TRE95e1_
Machine Functions
Switching-on
Once the main switch Q25 has been switched on the transformer T1 is supplied with a mains voltage. The
primary side can be adjusted to a value between 180 Va.c. and 440 V a.c. to meet the differing voltages.
It is protected by fuses F1 and F4.
The frequency converters are also supplied with a voltage.
As soon as the transformer is connected to the power supply emergency-stop loop is activated.
Emergency-stop loop
The voltage of 25 Va.c. fused by F3 supplies the evaluator A81 of the safety bars via contacts 13-14 of
motor protecting switch F1M (hydraulic motor) and pressure regulator B71. The second evaluator for the
safety bars for the vertical movements is in that condition bridged by relay K75 and will become active
only during the lowering of the pallet.
Another safety means is relay K5. When the thermal insulation contact of the pallet motor (M6) or the
motor of the aligning gauge (M8) is triggered relay K5 will be switched off which causes the emergency-
stop loop to be interrupted. When relay K5 is active the evaluators of light barriers A35 and A60 are
scanned. Besides, depending upon the type , the emergency-stop loop includes one or two emergency-
stop pushbuttons and switch „Voltage OFF“ (S44). When all conditions have been met lamp H42 on the
control unit lights up and safety relay A01 is ready for operation.
This state requires the following basic conditions:
Color Position Designation
--- Tower Pressure regulator (B71) active

yellow Evaluator(s)
Safety bars Evaluators are ready for operation
yellow K5 relays Termal contacts of motors o.k.
green 2 x Evaluator
safety light barriers Evaluators ready for operation, self-test o.k.
--- BDT +ASL Emergency-stop pusbutton unlocked
green A01 relay
TRE95e1_ / 29.02.1999
Ready for operation
When switch S13 „control voltage ON“ is actuated safety relay A01 is activated by the two N/C contacts
K02 and K03. The make contact of A01 contact 13-14 switches on contactors K02 and K03. The user is
informed by the green lamp H13 „ready for operation“.
The grippers close and move upward. After that, the following basic conditions are present:
Color Position Designation
green TRN card Voltage +24V switched on

green PS5 card Voltage +5V switched on
green TC02 Voltage +25V switched on
When the pallet is in basic position „at table height and rear position“ the following LEDs must be active:
LED Position Designation Switch. element
V5 TC02 Pallet rear stop B6

V6 TC02 LS pile edge A2
V13 TC02 Aligning gauge slowly (only fully automatic) B29
V16 TC02 Pallet front and rear slowly B4
V20 TC02 Pallet in table level B10
V21 TC02 Aligning gauge at rear B12
in addition, when there is no high pile between the gauges:

V11 TC02 Pile height A1
V23 TC02 LS lower slowly A5
and, if switched on:

V1 TC02 Blowing air during piling S20
V22 TC02 Blowing air only table height S20
V14 TC02 Holding-down function switched on S19
E145:
V40 TC02 Air supply ON Y11
E185:
V40 TC02 Air supply ON Y11
V36 TC02 Blowing air supply ON Y11a
The blowers are switched on by other contacts of contactors K02 and K03.
29.02.1999 / TRE95e1_
Manual Pallet Movements
Lower pallet manually (from table height)
Basic conditions:
Transomat ready for operation

Pallet at rear final position
Function Switch.element LED Circuit
Press pushbutton „lower pallet“ . S 15 + V2+ 8.1

Safety bars B78 (only E145) and B78a
are switched active by K75. K75 + 4.3
TRI „A“ card connects hydraul. valve „Lower“ 10.2
via relay K75 . YH3+ 10.3
and the input ramp for the hydr. control card
by relay „Proportional valve ON“. K6+ (on K6) 10.8
In addition, when there is no pile in the Transomat 10.7
nominal value 3 of hydr. control K7 + (on K7) 10.6
card is requested via relay „fast speed“
The control card controls the proportional
valve corresponding to the ramp control. YH6+ 10.5
The pallet lowers until proximity switch
bottom is reached or B2+ V8 + 6.3
„lowering“ pushbutton is no longer pressed. S 15 - V2- 8.1
Immediately after the lowering movement
has been started it is recognized that the
pallet is below table height. B8+ V 17 + 6.5
TRE95e1_ / 29.02.1999
Lift pallet - (pallet is at bottom position)
Basic conditions:

Pallet ar rear final position
Function Switch.element LED Circuit
Press key „lift pallet“. S 14 + V 10 + 8.2

Card TRI „A“ activates motor contactor K1M+ 10.8
The hydraulic motor drives the hydr. pump. M1+ 2.3
Relay „Proportional valve ON“ switches K6 + (on K6) 10.8
the hydr. ctrl. card via input „ramp“. 10.7
By relay „fast speed“ the nominal value 3 K7 + (on K7) 10.4
of the hydr. control card is requested. 10.6
The control card controls proportional valve
in accordance with ramp control YH6+ 10.5
The pallet is lifted.
The pallet moves while S14 is actuated. S 14 - V 10 - 8.2
or
the pallet moves fast until detection „pallet under B8- V 17- 6.5
table“ is actuated.
relay "fast speed" is switched of. K7 - (on K7) 10.4
the pallet moves slow until detection „table height" B 10 - V 20- 6.5
is actuated.
Motor contactor and proportional valve ON are K1M- 10.8
switched off. K6- (on K6) 10.8
Hydraulic motor is shut off. M1- 2.3
Pallet is then at „table height“.
- approx. 5 mm below the level of the
side table of the cutter.
The switching rail for B 8 (table height) can be shifted.
To move the pallet further upward, press pushbutton „lift pallet“ again.
Press „lift pallet“ , S 14 + V 10 + 8.2
Card TRI „A“ activates motor contactor K1M+ 10.8
Hydraulic motor drives hydr. pump. M1+ 2.3
Relay „Proportional valve ON“ switches K6 + (on K6) 10.8
the hydr. ctrl. card via input „ramp“. 10.7
Via relay „fast speed“ the nomin. value 3 K7 + (on K7) 10.4
of hydr. control card is requested. 10.6
The control card controls proportional valve
in accordance with ramp control YH6+ 10.5
The pallet can be lifted until
or limit switch „pallet at top“ has been reached. B1+ V4+ 6.2
Motor contactor and K1M- 10.8
hydraulic motor are shut off. M1- 2.3
Relay „Proportional valve ON“ is switched off. K6- (on K6) 10.8
29.02.1999 / TRE95e1_
Advance pallet (from initial position)
Conditions:
Function Switch. element LED Circuit
Press pushbutton „Pallet advance“ S 16 + V3+ 8.3

Aligning gauge is moved upward. Y7a+ V31+ 11.3
Reed contact „align. gauge at top“ is activated B9+ V19+ 6.7
The counter gauge is simultaneously lifted Y4b + V32 + 11.5
Card TRI „C“ opens the brake by relay „brake K 20 + 13.8
pallet motor“. Y 20 + 13.8
The frequency converter is enabled K 18 + V 45 + 13.3
„fast speed“ relay is activated. K 17 + V 43 + 13.2
The pallet starts at slow speed. U6+ (am FU) 2.4
only with fully autom. operation (from V1.4)
The pallet motor is accelerated
according to the „acceleration time“ preset (C012) M6+ 2.4
and the motor moves the pallet at „fast speedl“
(presetting by C038). By potentiometer
„speed of pallet“ this preset maximum speed
can be reduced. R 11 13.6
The pallet is advanced until limit switch
„Pallet front slowly“ has been detected. B4+ V 16 + 7.2
Then the pallet speed is reduced according
to presetting of „deceleration time“ (C013)
until „slow speed“ has been reached.
Pallet moves while light barrier
„pile edge“ remains unobstructed and A2- V6- 7.6
„advance“ pushbutton remains actuated. S 16- V 3- 8.3
Limit switch „pallet at front stop“ limits the
travel distance. B3+ V7+ 7.2
FU enabling is switched off. K 18 - V45 - 13.3
Pallet stops.
TRE95e1_ / 29.02.1999
Return pallet (from front position)
Conditions:
Press pushbutton „return pallet“. S 17 + V9+ 8.4

Aligning gauge is moved upward, unless at top. Y7a+ V31+ 11.3
Reed contact „align. gauge at top“ is activated B9+ V19+ 6.7
The counter gauge is simultaneously lifted, Y4b + V32 + 11.5
unless it is already at the top.
Reed contact „counter gauge“ is activated. B7 + V18 + 6.6
Pallet motor“. Y 20 + 13.8
By relay „return stroke“ the frequency converter
is informed that direction of travel has changed. K 19 + V 41 + 13.5
The pallet moves back at slow speed . U6+ (at FU) 2.4
only with fully autom. operation (from V1.4)
According to the „acceleration time“ preset
(C012)the pallet motor is accelerated. M6+ 2.4
When limit switch „front slowly“ is no longer
actuated the frequency converter will be B4- V 16 - 7.2
switched over to high speed by „fast speed“ relay
(presetting by C038).
By potentiometer „pallet speed“
the preadjusted speed can be reduced. R 11 13.6
Pallet moves back at high speed, until limit switch
„Pallet rear slowly“ has been detected. B5+ V 16 + 7.3
Pallet speed is reduced according
to the „deceleration time“ preset
(C013) until slow speed is reached.
The limit switch „Pallet at rear stop“ delimits
the travel distance. B6+ V5+ 7.4
FU enabling is switched off. K 18 - V 45 - 13.3
The pallet motor stops M6- 2.4
The motor brake is switched off by relay K 20 - 13.8
„motor brake“. Y 20 - 13.8
The pallet stops at the rear limit

The aligning gauge is lowered. Y7b+ V 30 + 11.1
Counter gauge is lowered as well. Y4a+ V 46 + 11.8
29.02.1999 / TRE95e1_
Size Adjustment
Prior to using automatic operation the Transomat must be adjusted to the size of the material. This is done
by the size adjustment function.
Type 185 is supplied with automatic size adjustment. On type 145 the customer has the choice
between semi-automatic (standard) and fully automatic operation (option).
1,5 bar
Size adjustment in semi-automatic operation
Basic conditions:

and in home position
Following the operating instructions the operator

switches over to „clamping free“ S 23 + V 13 + 7.8 + 9.6
Magnetic valve „aligning gauge return“ is
switched on. Y2+ 12.7
When the operator releases the clamping
lever at the aligning gauge the piston rod of the
cylinder „adjustable gauge“ moves out at the
preset pressure of approx. 1.5 bars and is
supported at the final stop.
The operator pushes the aligning gauge to
the proper position for the piling process (incl.
prestress). A scale indicates the size.
At that point the align. gauge is locked again
on the piston rod.
Switch „clamping free“ is switched off. S 23 - V 13 - 7.8 + 9.6
Magnetic valve „aligning gauge advance“ is
shut off. Y2- 12.5
The aligning gauge returns to home position.
Size Adjustment in Fully-Automatic Operation
The operator only presets the bias voltage

at BCD switch „size adjustment“. S 25 9.8
TRE95e1_ / 29.02.1999
Automatic Operation
The sequence depends on the height of the pile of material.

Two situations are described:
High pile = The Transomat pallet must be lifted before the material can be unloaded.
Low pile = Sloping run towards the bottom and the material pile.
High pile
Basic conditions:

Pallet is at rear initial position
Automatic unloading is started by actuation of

pushbutton „Autom. oper. ON“ S 12 + V 12 + 9.1
or by pushbutton „Autom. oper. ON“ of the operat.
unit at the aligning gauge S 24 + V 12 + 9.5
The operator receives an acknowledgement by
Lamp „Autom. oper.“ on the main control panel H 12 + 9.2
Lamp „Autom. oper.“ on the control panel at the
aligning gauge H 24 + 9.7
When function „blowing air during unloading“ S 20 V1+ 8.7

or „blowing air only table height“ has been preselected. S 20 V 22 + 8.7
only 145:
Pallet air supply is switched off. Y 11 - V40 - 10.1
only 185:
Air supply is switched on
and switched over to suction air. Y 11 - V 40 - 10.1
When function „holding-down clamp“ is selected, S 19 + V 14 + 8.5

it is lowered onto the material. Y9+ V35 + 12.1
only with fully autom. operation:

gauge motor“. Y136 + 14.7
The frequency converter is enabled K 58 + 14.3
The gauge advances at slow speed (C037). U8+ (am FU) 2.6
The aligning gauge advances according to the
„gauge time“ preset (TRI „A“ S1) and generates
a distance to the material loaded.
The frequency converter is locked. K 58 - 14.3
The brake is switched off. K 60 - 14.6
Y136 - 14.7
29.02.1999 / TRE95e1_
only with semi-automatic operation:

Magnetic valve „align. gauge advance“ is
switched on. Y8+ V 33 + 11.2
The align. gauge is lifted Y7a+ V 31 + 11.3
Reed contact „align. gauge at top“ is activated B9+ V 19 + 6.7
The counter gauge is lifted at the same time. Y4b+ V 32 + 11.5
Reed contact „counter gauge at top „ is activated B7+ V 18 + 6.6
Attention!
If any of these two messages is not given the Transomat unit will not continue in the
automatic cycle.
Magnetic valve „align. gauge advance“ is switched off. Y8- V 33 - 11.2
Light barrier „pile height“ scans if the pallet
must be lifted before it can be unloaded. A1+ V 11 + 7.5
Card TRI „A“ controls the motor contactor K1M+ 10.8
The hydr. motor drives the hydr. pump. M1+ 2.3
By relay „proportional valve ON“ the ramp K6+ (on K6) 10.8
input for hydr. control card is activated. 10.7
By the „fast speed“ relay nomin. value 3 K7+ (on K7) 10.4
of hydr. control card is requested. The control card controls 10.6
the proportional valve according to the ramp control YH6+ 10.5
The pallet is lifted sufficiently to be free. A5+ V23 + 7.6
Motor contactor and relay „proportional valve ON“ K1M- 10.8
are switched off. K6- (on K6) 10.8
The hydraulic motor is switched off. M1- 2.3
„fast speed“ relay is activated. K 17 + V 43 + 13.2
The pallet motor is accelerated
according to the „acceleration time“ preset (C012) M6+ 2.4
and the motor moves the pallet at „fast speedl“ (preset-
ting by C038). By potentiometer „speed of pallet“ this
preset maximum speed can be reduced. R 11 13.6
The pallet is advanced until limit switch
„Pallet front slowly“ has been detected. B4+ V 16 + 7.2
Then the pallet speed is reduced according to presetting
of „deceleration time“ (C013) until „slow speed“ has
been reached. Limit switch „Pallet front slowly“ delimits
„motor brake“. The pallet stops. Y 20 - 13.8
Card TRI „A“ switches on hydr. valve K75 + 10.2
„lower“ by relay K75. YH3+ 10.3
Besides the ramp input for the hydr. K6 + (on K6) 10.8
control card by relay „Proportional valve ON“ 10.7
and by relay „fast / slow“ nominal value 3 of hydr. K7 + (on K7) 10.4
control card.The control card controls the proportional 10.6
valve according to the ramp control. YH6+ 10.5
TRE95e1_ / 29.02.1999
When pile height of material has been detected by

light barrier „lower slowly“ the hydr. control card A5- V 23 - 7.6
is instructed by relay „fast/slow“ to switch over K7- (on K7) 10.4
to slow lowering speed. YH6- 10.5
Light barrier „Pile height“ initiates the lowering A1- V 11 - 7.5
movement to be stopped. After the preset „post-lowering time“
has been preselected
only 145:
air supply is switched on. Y 11 + V40 + 10.1
only 185:
air supply is switched on Y 11 a + V 36 + 10.0
and switched over to blowing air. Y 11 + V 40 + 10.1
Counter gauge and Y4a+ V 46 + 11.8

aligning gauge are lowered. Y7b+ V 30 + 11.1

the clamp is lifted . Y9- V35 - 12.1
only with fully autom. operation:

When Transomat pallet has been positioned
above the pile of material
(end position at front) the aligning gauge will
move behind the material to be unloaded.
The gauge is advanced at slow speed (C037) . U8+ (at FU) 2.6
The gauge motor is accelerated according to
the „acceleration time“ preset (C012) . M8+ 2.6
As soon as light barrier „size adjustment“ A6+ V 15 + 6.8
detects the end of the material the gauge speed
is reduced according to the value preset as a
„deceleration time“ (C013) until „slow speed“
has been obtained.
If A6 is not continously detecting material,
the cycle will be interupted.
Once the gauge afterrun time (TRI C S3) has expired
and afterrun by switch „size adjustment“ (clamping) S25 9.8
FU enabling is switched off. K 58 - 14.3
The motor brake is switched off K 60 - 14.6
and locks the gauge. Y136 - 14.7
The gauge stops.
If no paper is loaded the final disconnection
is made by the second switching cam of switch
„Aligning gauge at rear/at front“ B12 7.7
The counter gauge is advanced first. Y5+ V 42 + 11.7

After that, the aligning gauge is advanced. Y8 + V 33 + 11.2
29.02.1999 / TRE95e1_
only with semi-automatic operation:

Magnetic valve ""Aligning gauge return" is switched off Y2- 12.7
Magnetic valve "Aligning gauge advance" is switched on Y 3 + 12.5
Attention!
Adjust exhaust air throttles and gauge time to ensure
that the counter gauge is the first to reach the material!
only 145:
After activation of magnetic valve
„lower pallet tips“ the front edge of
the Transomat pallet is lowered. Y6+ V 44 + 12.3
Pallet motor“. Y 20 + 13.8
The pallet moves back at slow speed . U6+ (at FU) 2.4
(C012)the pallet motor is accelerated. M6+ 2.4
When limit switch „front slowly“ is no longer
actuated the frequency converter will be B4- V 16 - 7.2
switched over to high speed by „fast speed“ relay
The limit switch „Pallet at rear stop“ delimits
The pallet stops.
only 145:
By switching off magnetic valve „lower / lift
pallet tips“ the front edge of
the pallet is lifted. An even basis has been prepared
for piling up the material. Y6- V 44 - 12.3
TRE95e1_ / 29.02.1999
Limit switch „Aligning movement OFF“ not activated

The aligning movement is carried out: B 27 - V 24 - 6.1
The aligning gauge moves back according to
the „gripper time“ TRI „A“ S2 preset. Y8- V 33 - 11.2
The aligning gauge is lowered together with
magnetic valve „free stroke“. Y1+ 11.4
The aligning gauge approaches the material again. Y8+ V 33 + 11.2
Once the aligning movement is finished the aligning
gauge moves back. Y8- V 33 - 11.2
Magnetic valve „free stroke“ is switched off. Y1+ 11.4
Magnetic valve „counter gauge advance“ is
switched off and the gauge returns to home Y5- V 42 - 11.7
position.
only fully automatic operation:
Once the unloading and possible aligning has
been finished the aligning gauge is returned
to home position.
Card TRI „C“ opens the brake by relay K 60 + 14.6
„Brake gauge motor“. Y136 + 14.7
Relay „return movement“ requests the
changed direction of rotation of the K 59 + 14.5
gauge motor.
„Fast speed“ relay is switched on. K 57 + 14.2
The frequency converter is enabled. K 58 + 14.3
The gauge starts at slow speed (C037) . U8+ (at FU) 2.6
(C012)the gauge motor is accelerated. M6+ 2.6
The gauge moves back at high speed
(presetting C038).
As soon as switch „aligning gauge slowly“
is reached the gauge speed is reduced B 29 + V 13 + 7.8
The limit switch „Aligning gauge at rear/at front“
delimits the travel path. B 12 + V 21 + 7.7
The gauge is stopped.
Card TRI „A“ switches on hydraulic valve K75 + 10.2

„lower“ by relay K75 YH3+ 10.3
Besides, the ramp input for hydr. control card K6 + (on K6) 10.8
is switched on by relay „Proportional valve ON“ 10.7
and by relay „fast speed“ K7 + (on K7) 10.4
nominal value 3 of hydr. control card is requested. 10.6
The control card controls the proportional valve
according to the ramp control. YH6+ 10.5
are switched active by K75 . K75 + 4.3
The pallet is lowered below table height. B 8+ V 17 + 6.5
Card TRI „A“ controls the motor contactor. K1M+ 10.8
29.02.1999 / TRE95e1_

The „ramp“ input for hydr. control card K6+ (on K6) 10.8
is switched via relay „proportional valve ON“. 10.7
according to the ramp control YH6+ 10.5
The pallet moves until detection
„table height“ is no longer actuated. B 10 + V 20 + 6.4
relay „proportional valve ON“
are switched off. K6 - (on K6) 10.8
The hydraulic motor is switched off M1- 2.3
The pallet is now at „table height“ approx. <5 mm
below the level of the side table of the cutter.
The switching rail for B 8 can be shifted.
only 145:
or „blowing air only table height“ has been selected, S 20 V 22 + 8.7
it will be switched on again. Y 11 + V40 + 10.1
only 185:
and changed over to blowing air Y 11 + V 40 + 10.1
TRE95e1_ / 29.02.1999
Small pile
If light barrier „pile height“ has not detected

a high pile of material the pallet is lowered
and simultaneously advanced.
Automatic unloading is started by actuation of

pushbutton „Autom. oper. ON“ S 12 + V 12 + 9.1
or by pushbutton „Autom. oper. ON“ on the control
panel of the aligning gauge. S 24 + V 12 + 9.5
The operator receives an acknowledgement by
lamp „autom. operation“ on the main control panel and H 12 9.2
lamp „autom. operation“ on the control panel of the
aligning gauge. H 24 9.7

or „blowing air only table height“ has been selected S 20 V 22 + 8.7
only 145:
pallet air supply is switched off. Y 11 - V40 - 10.1
only 185:
air supply is switched on
and switched over to suction air. Y 11 + V 40 - 10.1

it is lowered onto the material. Y9+ V35 + 12.1
The align. gauge advances according to the
„gauge time“ preset (TRI „A“ S1) and
generates a distance to the material inserted. Y8+ V 33 + 11.2
The align. gauge is lifted Y7a+ V 31 + 11.3
Reed contact „align. gauge at top“ is activated B9+ V 19 + 6.7
The counter gauge is simultaneously lifted. Y4b+ V 32 + 11.5
Reed contact „Counter gauge at top „is activated. B7+ V 18 + 6.6
Attention!
If any of the messages is missing the Transomat unit will not continue the automatic
cycle.
Card TRI „A“ switches on hydr. valve K75 + 10.2
„lower“ by relay K75. YH3+ 10.3
Besides the ramp input for the hydr. K6 + (on K6) 10.8
control card by relay „Proportional valve ON“ 10.7
and by relay „fast / slow“ K7 + (on K7) 10.4
nominal value 3 of hydr. control card 10.6
are also switched active by K75. K75 + 4.3
29.02.1999 / TRE95e1_
first cycle (first ream)

If limit switch „pallet at bottom“ is detected B2+ V8+ 6.5
before the pile height has been sensed
the gauge movements including the fixing
(prestress) of the material are performed before
the pallet is finally lowered.
For this purpose, the gauges are moved together,
after that the lowering movement is started at hight
speed. When light pushbutton „slow“ is detected
relay „fast speed“ is switched off and pallet
is lowered at slow speed after the ramp has been
terminated, until pallet is switched off by
limit switch „at bottom“.
B27
fast lowering
A5 slow lowering
B2 stop at bottum
H12/H24 flashing
Pushbuttons „Autom. oper. ON“ are flashing. H 12 9.2

H 24 9.7
To continue operation one of these pushbuttons
must be pressed. S 12 + / S 24 + V 12 + 9.1
second and further cycles

When pile height of material has been detected by
light barrier „lower slowly“ the hydr. control card A5- V 23 - 7.6
is instructed by relay „fast/slow“ to switch over K7- (on K7) 10.4
to slow lowering speed. YH6- 10.5
Light barrier „Pile height“ initiates the lowering A1- V 11 - 7.5
movement to be stopped.
After the preset „post-lowering time“
TRI „A“ S3 and the time preset at
BCD switch „Unloading height“ has expired
the hydraulic control is switched off. S 18 9.4
K 75 - 10.2
YH3- 10.3
K6- (on K6) 10.8
Simultaneously with advance movement

The frequency converter is enabled. K 18 + V 45 + 13.3
TRE95e1_ / 29.02.1999

(C012) the pallet motor is accelerated, M6+ 2.4
until the high speed has been reached
Pallet advances rapidly until
limit switchs „Pallet front slowly“ is detected. B4+ V 16 + 7.2
„Fast speed“ relay is switched off. K 17 - 13.2
(C013) until slow speed is reached
The limit switch „Pallet front slowly“ delimits the

The pallet stops.
only 145:
When function „Blowing air during unloading“ S 20 V1+ 8.7
has been preselected it is switched on now. Y 11 + V40 + 10.1
only 185:
When function „Blowing air during unloading“ S 20 V1+ 8.7
and changed over to blowing air. Y 11 + V 40 + 10.1
Counter gauge and Y4a+ V 46 + 11.8

aligning gauge are lowered. Y7b+ V 30 + 11.1
the clamp is lifted at that moment. Y9- V35 - 12.1
When the Transomat pallet has been positioned
over the pile of material which has already been unloaded
(end position at front), the align. gauge will move
behind the material unloaded.
Card TRI „C“ opens the brake by relay „Brake K 60 + 14.6
The gauge starts at slow speed (C037). U8+ (at FU) 2.6
(C012) the gauge motor is accelerated. M6+ 2.6
When light pushbutton „size adjustment“ A6+ V 15 + 6.8
detects the end of the material the gauge speed
is reduced to the „deceleration time“ preset
(C013) until slow speed is reached. K 57 - 14.2
After both the gauge afterrun time and the afterrun
set by switch for size adjustment have elapsed
(prestress) S25 9.8
29.02.1999 / TRE95e1_

The gauge stops.
If no paper is available the final cut-off is made
by the second switching cam of switch
„Aligning gauge at rear/at front“ . B12 7.7
The counter gauge is advanced first. Y5+ V 42 + 11.7

After that, the aligning gauge is advanced. Y8+ V 33 + 11.2
Attention!
Adjust exhaust air throttles and gauge time to ensure
that the counter gauge is the first to reach the material!
only 145:
After activation of magnetic valve
„lower pallet tips“ the front edge of
the Transomat pallet is lowered. Y6- V 44 - 12.3

The pallet starts to move back at slow speed
(C037) . U6+ (am FU) 2.4
(C012)the pallet motor is accelerated to high speed M6+ 2.4
the preadjusted speed can be
reduced. R 11 13.6
The limit switch „Pallet at rear stop“ delimits the
The pallet motor stops. M6- 2.4
The pallet stops.
only 145:
By switching off magnetic valve „lower/lift
pallet tip“ the front edge of the pallet is lifted.
An even basis has been prepared for unloading
the material. Y6- V 44 - 12.3
TRE95e1_ / 29.02.1999
If limit switch „aligning movement OFF“ not active

aligning movement is triggered : B 27 - V 24 - 6.1
The aligning gauge moves back according to
the „gripper time“ TRI „A“ S2 preset. Y8- V 33 - 11.2
The aligning gauge is lowered together with
magnetic valve „free stroke“. Y1+ 11.4
The aligning gauge approaches the material
again. Y8+ V 33 + 11.2
Once the aligning movement has been performed
the aligning gauge moves back. Y8- V 33 - 11.2
Magnetic valve „free stroke“ is switched off. Y1+ 11.4
Magnetic valve „counter gauge advance“ is switched
off and gauge returns to home position. Y5- V 42 - 11.7

Once the unloading and possible aligning has
been finished the aligning gauge is returned
to home position.
Relay „return movement“ requests the modified
direction of rotation of gauge motor. K 59 + 14.5
The frequency converter is enabled. K 58 + 14.3
The gauge starts to move back at slow speed (C037). U8+ (at FU) 2.6
(C012)the gauge motor is accelerated. M6+ 2.6
When switch „aligning gauge slow“
is reached the gauge speed is reduced B 29 + V 13 + 7.8
The limit switch „Aligning gauge at rear/at front“
delimits the travel path. B 12 + V 21 + 7.7
The gauge stops.
Card TRI „A“ controls the motor contactor K1M+ 10.8
By relay „proportional valve ON“ the ramp K6 + (on K6) 10.8
input for hydr. control card is switched to active. 10.7
and relay „fast speed“ requests the nominal K7 + (on K7) 10.4
value 3 of the hydr. control card. 10.6
The pallet moves fast until detection „pallet under B8- V 17- 6.5
table“ is actuated.
relay "fast speed" is switched of. K7 - (on K7) 10.4
the pallet moves slow until detection „table height" B 10 - V 20- 6.5
is actuated.
29.02.1999 / TRE95e1_
Motor contactor and proportional valve ON are K1M- 10.8

switched off. K6- (on K6) 10.8
Hydraulic motor is shut off. M1- 2.3
Pallet is then at „table height“.
relay „proportional valve ON“
are switched off. K6 - (on K6) 10.8
The hydraulic motor is switched off M1- 2.3
The pallet is now at „table height“ approx. <5 mm
below the level of the cutter side table.
only 145:
it will be switched on again. Y 11 + V40 + 10.1
only 185:
and turned over to blowing air. Y 11 + V 40 + 10.1
TRE95e1_ / 29.02.1999
Part Location Path Component Function
A1 Crosspiece 7.5 Light barrier Scanning Pile height

A2 Pallet 7.6 Light barrier Scanning Pile edge
A5 Crosspiece 7.6 Light pushbutton Lowering slow
A6 Aligning gauge 6.8 Light barrier Size adjustment
A01 Control board 4.7 Starting device Monitoring Emergency-stop loop
A31 Aligning gauge 5.1 Safety light barrier Monitoring: Pallet front at top
A32 Counter gauge 5.0 Safety light barrier Monitoring: Pallet front at top
A33 Aligning gauge 5.4 Safety light barrier Monitoring : Pallet front at bottom
A34 Counter gauge 5.2 Safety light barrier Monitoring: Pallet front at bottom
A35 Control board 5.4 LS-Control unit Evaluator Monitoring Pallet at front
A36 Counter gauge 5.6 Safety light barrier Monitoring: Pallet lateral at top
A37 Counter gauge 5.5 Safety light barrier Monitoring: Pallet lateral at top
A38 Counter gauge 5.8 Safety light barrier Monitoring: Pallet lateral at bottom
A39 Counter gauge 5.7 Safety light barrier Monitoring: Pallet lateral at bottom
A40 Control board 5.5 LS-Control unit Evaluator Monitoring Pallet lateral
A67 Control board 4.1 SL-Control unit Evaluator Switching rail Pallet vertical
A70 Control board 10.5 P.c. board Control unit Hydraulic system
A81 Control board 4.5 SL-Control unit Evaluator Switching rails Pallet horizontal
AR Motherboard TC02 3.0 P.c. board Computer card
B1 Tower 6.1 Proximity sensor Position indicator Pallet at top
B2 Tower 6.3 Proximity sensor Position indicator Pallet at bottom
B3 Crosspiece 7.2 Proximity sensor Position indicator Pallet front stop
B4 Crosspiece 7.2 Proximity sensor Position indicator Pallet front slowly
B5 Crosspiece 7.3 Proximity sensor Position indicator Pallet rear slowly
B6 Crosspiece 7.4 Proximity sensor Position indicator Pallet at rear stop
B7 Counter gauge 6.6 Proximity sensor Position indicator Counter gauge at top
B8 Tower 6.5 Proximity sensor Position indicator Pallet below table height
B9 Aligning gauge 6.6 Proximity sensor Position indicator Aligning gauge at top
B10 Tower 6.4 Proximity sensor Position indicator Pallet Table height
B11 Gauge support 7.1 Proximity sensor Position indicator aligning gauge at front
B12 Gauge support 7.7 Proximity sensor Pos. indicator aligning gauge at rear/at front
B27 Tower 6.0 Proximity sensor Position indicator Aligning movement off
B29 Aligning gauge 7.8 Proximity sensor Aligning gauge slow travel
B71 Tower 4.2 Pressure sensor Pressure monitoring Pneumatic system
B78 Pallet 4.3 Switching rail Switching rail Vertical movement
B78a Pallet 4.3 Switching rail Safety rail Horizontal movement
B82 Pallet 4.5 Switching rail Safety rail Horizontal movement
B82a Pallet 4.5 Switching rail Safety rail Horizontal movement
B82b Pallet 4.5 Switching rail Safety rail Horizontal movement
F1 Control board 3.0 Fine-wire fuse Fusing Primary side Transformer
F1M Control board 2.3 Motor protect. switch Fusing Hydraulic motor
F2 Control board 3.1 Fine-wire fuse Fusing Secondary side Transformer
F2M Control board 2.2 Motor protect. switch Fusing blower motor
F4 Control board 3.0 Fine-wire fuse Fusing Primary side Transformer
F6 Control board 2.4 Fine-wire fuse Fusing Frequency converter
H12 Control panel 9.2 Signal lamp Indication Autom. operation
29.02.1999 / TRE95e1_
H13 Control panel 9.3 Signal lamp Indication Readiness for functioning
H24 Aligning gauge 9.7 Signal lamp Indication Autom. operation
H42 Control panel 4.7 Signal lamp Indication Emergency-stop loop free
K1M Control board 10.8 Contactor Start-up hydraulic motor
K02 Control board 4.8 Contactor Starting combination
K03 Control board 4.8 Contactor Starting combination
K5 Control board 4.1 Relay Scanning Winding earth contacts
K6 Control board 10.8 Relay Pallet stroke Ramp control
K7 Control board 10.4 Relay Pallet stroke Nominal position control
K17 Support. sledge 13.2 Relay Pallet run fast / slow
K18 Support. sledge 13.3 Relay Pallet run Controller Enabling
K19 Support. sledge 13.5 Relay Pallet run advance / return
K20 Support. sledge 13.8 Relay Brake Pallet motor
K57 Support. sledge 14.2 Relay Aligning gauge fast / slow
K58 Support. sledge 14.3 Relay Aligning gauge Controller Enabling
K59 Support. sledge 14.5 Relay Aligning gauge advance / rückwärts
K60 Support. sledge 14.6 Relay Brake Gauge motor
K75 Control board 10.2 Safety relay Activation MV lower pallet
M1 Tower 2.3 Motor Hydraulikmotor
M2 Tower 2.2 Gebläse Pallet luft
M6 Pallet 2.4 Motor Drive unit Pallet Horizontal run
M8 Gauge support 2.6 Motor Drive unit Aligning gauge
PS5 Motherboard TC02 3.0 P.c. board Power supply card 5V
Q25 Tower 2.0 Cam switch Master switch
R11 Control panel 13.6 Potentiometer Adjustment Pallet speed
S11 Control panel 4.7 Emergency-stop key Emergency-stop
S12 Control panel 9.1 Illumin. key Autom. oper. ON
S13 Control panel 4.9 Pushbutton Control voltage ON
S14 Control panel 8.2 Pushbutton Pallet lift
S15 Control panel 8.1 Pushbutton Pallet lower
S16 Control panel 8.3 Pushbutton Pallet advance
S17 Control panel 8.4 Pushbutton Pallet return
S18 Control panel 9.3 BCD switch Adjustment Unloading height
S19 Control panel 8.5 Selector switch Holding-down clamp ON
S20 Control panel 8.6 Selector switch Mode Pallet air supply
S21 Aligning gauge 4.7 Emergency-stop key Emergency-stop
S23 Aligning gauge 9.6 Selector switch Gauge clamping free
S24 Aligning gauge 9.5 Illumin. key Autom. oper. ON
S25 Aligning gauge 9.8 BCD switch Adjustment Bias voltage
S26 Pallet 4.1 Wind.earth contact Motor prot. Pallet motor
S28 Gauge support 4.1 Wind.earth contact Motor prot. Gauge motor
S44 Control panel 4.7 Pushbutton Control voltage aus
T1 Control board 3.1 Transformer Control transformer
TRI Motherboard TC02 P.c. board Interface-Card
TRN Motherboard TC02 3.1 P.c. board Power supply card 24V
U6 Support. sledge 2.4 Frequency converter Control Pallet drive unit
U8 Support. sledge 2.6 Frequency converter Control Linealdrive unit
V1 Control board 3.2 Gleichrichter Gleichrichtung 25V
V1 Motherboard TC02 8.7 Light emitting diode Function indicatorsanzeige
V2 Motherboard TC02 8.1 Light emitting diode Function indicator
TRE95e1_ / 29.02.1999

X00 Tower Klemmleiste Einspeisung
X0 Tower Terminal strip Hauptconnection
X1 Control board Terminal strip Verteilung Steuerelemente Tower
X2 Control board Terminal strip Connection-Control Frequency converter
X3 Control board Terminal strip Connection Pallet, Träger
X4 Control board Terminal strip Connection Sicherheitslight barrier
X5 Control board Terminal strip Connection Abstapellineal
X9 Control board Terminal strip Connection Control panel
X10 Control board Terminal strip Connection Power supply FU
X11 Control board Terminal strip Connection Hydraulic motor
X12 Control board Terminal strip Connection Hydraulic control
X13 Control board Terminal strip Connection Blower motor
X14 Control board Terminal strip Connection Pneumatic control unit
X20 Support. sledge Terminal strip Distributor Activation Frequency converter
X24 Support. sledge Plug-in connection Connection Pneumatic block
X30 Support. sledge Terminal strip Distributor Pallet, Support
X32 Crosspiece Terminal strip Distributor Safety rail
29.02.1999 / TRE95e1_
X33 Pallet Plug-in connection Isolating point Pallet

X40 Support. sledge Terminal strip Distributor Safety light barrier
X41 Counter gauge Plug-in connection Transfer point Counter gauge
X42 Counter gauge Terminal strip Distribution Counter gauge
X43 Counter gauge Plug-in connection Intermediate plug
X50 Support. sledge Terminal strip Distributor Aligning gauge
X51 Aligning gauge Plug-in connection Transfer point Aligning gauge
X52 Aligning gauge Terminal strip Sub-division Aligning gauge
X90 Tower Plug-in connection Transfer point Control panel
XTC1 Motherboard TC02 Plug-in connection Input signals (Sensor system)
XTC2 Motherboard TC02 Plug-in connection Input signals (Sensor system)
XTC4 Motherboard TC02 Plug-in connection Input signals (Timer)
XTC9 Motherboard TC02 Plug-in connection Power supply Motherboard
XTC21 Motherboard TC02 Plug-in connection Transistor output signals
XTC22 Motherboard TC02 Plug-in connection Transistor output signals
XTC41 Motherboard TC02 Plug-in connection Connection Relay contacts
XTC42 Motherboard TC02 Plug-in connection Connection Relay contacts
Y1 Support. sledge 11.4 Magnetic valve Free stroke
Y2 Support. sledge 12.7 Magnetic valve Aligning gauge return
Y3 Support. sledge 12.5 Magnetic valve Aligning gauge advance
Y4a Support. sledge 11.8 Magnetic valve Counter gauge lower
Y4b Support. sledge 11.5 Magnetic valve Counter gauge lift
Y5 Support. sledge 11.7 Magnetic valve Counter gauge advance
Y6 Support. sledge 12.3 Magnetic valve Pallet tips lower
Y7a Support. sledge 11.3 Magnetic valve Aligning gauge lift
Y7b Support. sledge 11.1 Magnetic valve Aligning gauge lower
Y8 Support. sledge 11.2 Magnetic valve Aligning gauge advance
Y9 Support. sledge 12.1 Magnetic valve Holding-down clamp lower
Y10 Support. sledge 12.2 Magnetic valve Close grippers
Y11 Tower 10.1 Magnetic valve Blowing air ON
Y11a Tower 10.0 Magnetic valve Suction air ON (S/D-blower)
Y20 Pallet 13.8 electro-magn.brake Brake Pallet motor
Y136 Gauge support 14.7 electro-magn.brake Brake Gauge motor
YH3 Tower 10.3 Magnetic valve Seat valve, Hydraulic system
YH6 Tower 10.5 Magnetic valve Proportional valve Hydraulic system
TRE95e1_ / 29.02.1999
LED Function Element Basic condition
V1 selector switch pallet air supply S20 OFF or ON

V2 pushbutton pallet lower S15 OFF
V3 pushbutton pallet advance S16 OFF
V4 pallet at top B1 OFF
V5 pallet rear stop B6 ON
V6 light barrier: pile edge A2 ON
V7 pallet front stop B3 OFF
V8 pallet at bottom B2 OFF
V9 pushbutton pallet return S17 OFF
V10 pushbutton Pallet lift S14 OFF
V11 light barrier: pile height A1 OFF or ON
V12 pushbutton Automatic ON S12
S24
V13 fully automatic: aligning gauge slow B29 ON
semy automatic: size adjustment S23 OFF
V14 selector switch holding-down clamp S19 OFF or ON
V15 fully automatic: light barrier size adjustment A6 OFF
semy automatic: aligning gauge at front B11 OFF
V16 pallet front or rear slowly B4, B5 ON
V17 pallet below table height B8 OFF
V18 counter gauge at top B7 OFF or ON
V19 aligning gauge at top B9 OFF
V20 pallet at table height B10 ON
V21 fully automatic: aligning gauge rear / front B12 ON
semy automatic: Anschlaglineal rear B12 ON
V22 selector switch pallet air supply S20 OFF or ON
V23 light barrier: lowering slowly A5 OFF or ON
V24 aligning movement OFF B27 OFF
V30 aligning gauge down Y7b OFF

V31 aligning gauge up Y7a OFF
V32 counter gauge up Y4b OFF
V33 aligning gauge advance Y8 OFF
V34 gripper close Y10 OFF
V35 clamp down Y9 OFF
V36 air supply / suction (only TR 185) Y11a OFF or ON
V40 air supply ON Y11 OFF or ON

V41 pallet drive: pallet reverse K19 OFF
V42 counter gauge advance Y5 OFF
V43 pallet drive: pallet fast K17 OFF
V44 pallet tips lower Y6 OFF
V45 pallet drive: controler enabling K18 OFF
V46 counter gauge down Y4a OFF
29.02.1999 / TRE95e1_
Direction of mounting Direction of disassembleing
mechanical connestion
TRE95e1_ / 29.02.1999
Latest changes
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Version Date Changes
TRE95e1_ 29.02.199 genearal revision, create pdf-file KMei

TRE 145-185 (1995) 29-2-99 Service Descarga Derecho Ingles PDF

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TRE95e1_ / 29.02.

Imprint: File: TRE95e1_.pdf / first edition: 26.06.1995

Survey of the different types of Transomat machines ........................................... 3

Control System ..........................................................................................................6

Description of Function Cards ................................................................................. 7

Pneumatic System .................................................................................................. 11

Frequency Converter (FU) Lenze 8200 .................................................................. 14

Hydraulic System .................................................................................................... 17

Machine Functions .................................................................................................. 24

Latest changes ........................................................................................................ 49

Survey of the different types of Transomat machines

Options: GRF = gripper

E145-4 E145-6 E185-6 E185-7S

Size 80x120 105x145 105x145 122x164

View from the front

View from the rear

K19 TRN PS 5 AR TRI a TRI c 1

X10 X13 X11 X12 X14 X2 X3 X4 X5 X9

The transformer supplies the following secondary voltages:

Description of Function Cards

Plug-in Card „Positioning Computer“

Curent software version: TRI "A" TRI "C"

TRI "A" TRI "C"

Plug-in Card „Transomat Interface“

Plug-in Card „Transomat Interface“ (TRI-24) is a

Card Switch Semi-autom. Fully-autom. Meaning

TRI A S1 8 4 Gauge time

TRI C S1 0 0 Lift gauges prematurely

The „gauge time“ is meant as a steadying time in various situations:

The „gripper time“ has two effects:

The function „lift gauges prematurely“ has two states:

The function „Aligning ON/OFF“ has two states:

1. Relay A01 as a make combination with positively driven contacts.

LED 3 = red = interruption LSU

Selftest performed after supply voltage has been switched on

Valve Cylinder Function

(Y10) Y9 Y8 Y7a Y6 Y5 Y4b (Y3) (Y2) Y1

1.5 bar Free lifting

clamp Aligning gauge

Y10 Y5 Y7a Y6 Y8 Y4b Y9 Y2 Y3 Y1

Frequency Converter (FU) Lenze 8200

Transomat machines are fitted two different frequency converters. Lenze FU

In case a device must be replaced at the customer‘s: 9

has jumper position 4-3)

available as an auxiliary tool at every Polar agency. N

Information on the operation and adjustment of converter 8200

LED green red Indication

Programming unit „8201BB“ can be clipped onto the frequency converter.

The programming unit is fitted with the following pushbuttons:

STP Locking of frequency converter

Overwriting of the parameter set by factory calibration

Modification of current set of parameters

CODE Benennung Palette HA Palette VA Palette VA (V1.4) Lineal

C001 Type of operation 0 0 0 0

acceleration time deceleration time

The upward and downward movements of the

Control card EVR2A1P for proportional valve

LED green Ready for functioning contin.

Fixed setpoint 4 is not used for the control of Transomat E units.

The setting of the lower turning knob affects

At first, both turning knobs are turned ccw until

After that, move Transomat pallet downward. If

ramp time by ramp time by