Operating Manual

Operating Manual
NCK-1
Max-Paul-Straße 1 88525 Dürmentingen / Germany 02.06.1999 TR/MB/LM

Phone: +49 (0)7371 / 500-0 Fax: +49 (0)7371 / 500-111 en B 736.02/1
Mail: [email protected] Web: www.paul.eu Seite 1/45
Table of contents
1 Programming..............................................................................................................4
1.1 Switching on the CNC control....................................................................................4

1.2 Switching on the cross-cut system ...........................................................................4
1.3 Entering lengths and numbers of pieces to be cut.................................................4
1.4 Setting the operating mode (see also Trim Cut modes) .......................................5
1.5 Entering the trim cut length........................................................................................5
1.6 Entering the saw lifting (cutting) time .......................................................................5
1.7 Checking the entered lengths and numbers of pieces to be cut .........................5
1.8 Changing a counter reading ......................................................................................5
1.9 Deleting a fixed length ................................................................................................5
2 Operating the machine ..........................................................................................6
2.1 Automatic operating sequence..................................................................................6

2.2 Explanation of the display during sawing.................................................................7
2.3 Automatic trim cut (see also trim cut operating modes).......................................7
2.4 Function and setting of the mark-detection feature (Model KE) ..........................8
2.5 Computer error messages .........................................................................................9
2.6 Meaning of error messages .....................................................................................10
2.7 Operating modes .......................................................................................................15
2.8 Operation of the partial optimization program.......................................................15
2.9 System parameters ...................................................................................................17
2.10 System parameters (values)....................................................................................18
2.11 Parameters of Sorting System ................................................................................20
2.12 Meaning of the system parameters ........................................................................21
2.13 Sorting stations ..........................................................................................................31
2.14 Special functions........................................................................................................32
3 Malfunctions and trouble-shooting ....................................................................33
3.1 General........................................................................................................................33
3.2 Measuring station ......................................................................................................34
3.3 Cross-cut station........................................................................................................36
3.4 Feed system ...............................................................................................................39

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3.5 Input signals ...............................................................................................................40
3.5.1 Inputs (Run - Control) ..........................................................................................................40
3.5.2 Input interface E1..................................................................................................................41
3.5.3 Rotary encoder inputs .........................................................................................................41
3.6 Output signals ............................................................................................................42

3.6.1 Outputs (Run - Control).......................................................................................................42
3.6.2 Outputs (Cross-cut station)................................................................................................42
4 Special functions.....................................................................................................43
4.1 Automatic sequence cutting program ....................................................................43

4.2 Length correction.......................................................................................... 45

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1 Programming
1.1 Switching on the CNC control
Activating the main switch on the electrical switch cabinet ( 0 -> 1) supplies voltage to the CNC control.
The program is loaded from the inserted diskette and the following display appears:
NCK-1 7490-1.08 NCK-1 = Name of CNC control

7490 = Software number
1.08 = Version number
1.2 Switching on the cross-cut system
Some 2 sec. after pressing the green button the saw motor and the feed drive start to run. In order to
program the control, the feed must be stopped.
1.3 Entering lengths and numbers of pieces to be cut
1. Press the <l> key

The program number and the letter l appear on the display
2. Enter the required fixed length in mm and confirm with the <enter> key
3. Enter the number of pieces required

If the entered length is not already available, the counter reading 0 is displayed.
If the entered length is already available, the corresponding counter reading is displayed.
4. Confirm with the <enter> key
5. If another length is to be entered, follow points 1 - 4.
The order of the lengths is immaterial, since the computer sorts them automatically, starting with the
greatest length.
Special features:
The minimum length is 30 mm, the maximum length is 20000 mm.
A maximum of 30 lengths can be stored.
The counters can be set to a maximum of 32000 pieces. The counters count backwards and as soon as
they reach zero, the length concerned is deleted automatically.
In order to delete a length, one must either enter the reading 0000, as described above or the <del> key
must be pressed at the displayed length.

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1.4 Setting the operating mode (see also Trim Cut modes)
1. Press the <mod> key
the currently set operating mode is shown on the display
e.g. mod 42
2. Enter the new value and close with the <enter> key
1.5 Entering the trim cut length

1. Press the <trim> key
the currently set trim cut length is shown on the display
e.g. trim 50
2. Enter the new trim cut value and close with the <enter> key
If no trim cut is required, this can be set by means of the operating modes.
1.6 Entering the saw lifting (cutting) time

1. Press the <to> key
the currently set lifting time in 1/100 sec. appears on the display
e.g. to 10
2. Enter a new value and close with the <enter> key
1.7 Checking the entered lengths and numbers of pieces to be cut

1. Press the <prog> key
The display starts with the greatest length, the corresponding counter reading and also the program
number.
2. Press the <prog> key again
The display switches to the next length. If the <prog> key is pressed again when the length is being
displayed, the listing out of the lengths starts again from the beginning.
If an empty / deleted cutting list / program is selected, the message empty appears on the display.
1.8 Changing a counter reading

1. Press the <n> key
2. Enter the required number of pieces
3. Close with the <enter> key
1.9 Deleting a fixed length

The greatest fixed length is displayed
2. By pressing the <prog> key again the fixed length to be deleted can be selected.
3. When the fixed length to be deleted is displayed press the <del> key

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2 Operating the machine
2.1 Automatic operating sequence

A board is entered between the slowly turning rollers at the wood infeed side. As soon as the board is
behind the first roller, it is recognized by the 'beginning of wood' photoelectric barrier and the feed motor
speeds up. First of all the distance from the photoelectric barrier to the saw blade + the trim cut dimension
(if automatic trim cut is being used) appears on the digital LCD display. If the automatic trim cut is
switched off, the display shows the greatest entered length + distance from photoelectric barrier to saw
blade. The machine conveys the board to this size (sawing position) and then cuts it off. The actual value,
i.e. the current position of the board can be read off from the digital LCD display (2nd. readout on the LCD
display).
The saw cut is only made when the target value = the actual value, i.e. when both displays show exactly
the same value.
After cutting, the machine again takes the longest preset length as a target length. This continues until
either the board is finished or until a crayon line occurs on the board. The crayon lines are detected by the
luminescent scanner (only on Model KE), which is mounted at the level of the photoelectric barrier, and
the target value is then changed in accordance with the partial optimization program.
Caution!
It can occur that a board needs to be conveyed backwards. This happens mainly if the
greatest entered length is greater than the measurement between the photoelectric
barrier beginning of wood) and the saw blade, or if appreciably differing lengths are
programmed.
When a waste piece has been cut off, the roller after the saw blade is briefly raised and the offcut is blown
out. For offcuts at the end of the board the rollers before and after the saw blade are raised. As long as
there is still a board in the machine, another one can be entered. In this way work continues without
interruption. There must be a gap of at least 10 mm between 2 successive boards, otherwise the second
board will not be detected by the CNC control.

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2.2 Explanation of the display during sawing
Prog. 1 XXXX (= Display status - see system parameter 241)
1st. Display 2nd Display 3rd Display 4th Display
Target value in mm Actual value in mm Application Status
Application: 0 = Fixed length

1 = Board end
2 = Finger joint length
4 = Waste
6 = Long waste
8 = Trim cut
Status: 1 = Feed runs at feeding-in speed

2 = Positioning to trim cut - photoelectric barrier has detected wood
3 = Outfeed of previous piece before next cut
4 = Start up and outfeed of previous piece
5 = Wait and outfeed of previous piece before next cut
6 = Positioning to fixed length
7 = Saw rises
8 = Cut + blow out
9 = Cut + blow out + top roller control
2.3 Automatic trim cut (see also trim cut operating modes)
When working with automatic trim cut, the operating sequence is the same, except that the preset trim cut
is made first, and only then is the greatest length cut.

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2.4 Function and setting of the mark-detection feature (Model KE)
Placing the crayon lines on the wood occasionally causes serious problems.
This depends mainly on the wood being used.
There are 2 different materials used to mark the lines on the wood. They are, in detail:
1. A red wax crayon. The crayon is already pre-treated to be luminescent. Please use the crayon holder
supplied to apply the marks to the wood.
2. A red liquid, which is poured into a felt-tipped marker. Very narrow lines can be made on the wood
using this system. This is mostly suitable when working with program changeover via code lines.
Please do not over-fill the felt-tipped marker, or it will start to drip.
There is a crayon holder for the crayon, so that the crayons are not constantly breaking, and the hands are
not continually full of crayon bits. If there is too much wax sticking to the fingers, it can happen that prints
form on the wood. The luminescent scanner detects these spots and a cut can be made in the wrong
place.
For the same reason, one should always be careful that the crayons do not lie scattered about on the
wood. Another problem that can occur in marking is that the crayon lines can be spread by the roller or the
measuring roller. The luminescent scanner may possibly detect several crayon lines. The top roller or
measuring roller does in fact have a groove, so that this should not happen. However, it can happen
through incorrect settings in assembly, or when changing over for other cross-sections, that the
luminescent scanner no longer reads behind this line.
Please note that the luminescent scanner only detects the crayon lines on a short length. The light spot is
projected onto the wood. The light spot can be made visible by holding a sheet of white paper under the
lens of the luminescent scanner.
The sensitivity of the device can be set at the luminescent scanner. Do not set the sensitivity too high, or
all the wax flecks that might be there will be detected. If the sensitivity is turned down too far, there is a
danger that crayon lines will no longer be detected at a fast feed rate.
It can also happen that the lines are not detected because the wood is too warped or too narrow. For
warped wood, the lines are possibly only detected on the first or second half. Please ensure therefore that
the wood moves along the fence.

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2.5 Computer error messages
The corresponding error code is displayed for error messages.
Error 1-1 green start button not pressed
Error 2-1 Run - Control has tripped
Error 3-1 Protection device open
Error 4 -1 EMERGENCY-OFF button pressed
Error 190 - 194 DOS error
Error 195 - 60 no board end - photoelectric barrier in sawing station obscured

Error 195 -1
Error 197 - x too many crayon lines
Error 200 - x FIFO full
Error 201 - 1 Number of cuts reached (Optimisation)
Error 203 - x Wood too short
Error 207 - 80 Saw rocker not rising
Error 208 - 1 Saw rocker not in down position
Error 208 - 2 Photoelectric barrier in sawing station obscured

Error 209 - 3
Error 209 no lengths in the cutting list
Error 206- x Saw not down
Error 222 - 1 Cutting list full (Program 1 - 4 max. 30 lengths)
Error 222 - 2 Cutting list full (Program 9 max. 10 lengths)
Error 217- 1 No compressed air
Error 999 - x Axis parameters incorrect

(corrected automatically)
Error 213-2 Sorting buffer full
Error 214-1 Sorting alarm

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2.6 Meaning of error messages
Error 1 - 1 Start the installation with the green button
If you attempt to operate the machine without first turning power on to the electric control by pressing the
green start button, the CNC control will make you aware of it by displaying this message.
Before the cross-cut station can be started, all Emergency Stop buttons have to be released and the
protection hoods on the cross-cut and measuring stations must be closed. If your cross-cut station is
fitted with a saw blade door interlock, this must also be closed.
When the green start button is pressed, the safety relay R99 on the Run-Control board pulls in. By means
of the 24V DC control voltage, the main contactor in the electrical switch cabinet is caused to pull in and
apply power to the entire cross-cut system.
Error 3 - 1 Protection device open?
For safe working, all the covering hoods and safety interlocks must be properly closed.
Other possible causes:
Limit switches on protection devices not (fully) closed.
To be able to operate your cross-cut system safely, a certain number of limit switches or interlocks are
fitted depending on the size of the machine. Make sure that all limit switches are correctly connected and
linked to the CNC control.
Fault in the safety circuit
The limit switches / interlocks have a 24V DC power supply like the other sensors. Check this control
voltage and the power supply. A cable may possibly be broken.
Defective limit switch
One of the limit switch contacts (break contact) no longer closes correctly or is defective. It may be that
the contacts are no longer conducting (possibly because of oxidation).

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Error 4 - 1 EMERGENCY-STOP pressed?
An Emergency Stop button on the installation is pressed and locked.
Other possible causes:
Emergency-Stop circuit not (fully) connected
To facilitate bringing your cross-cut system to a stop as quickly as possible in the event of an emergency,
a number of Emergency Stop switches are provided, depending on the size of the machine concerned. It
should be checked that these are all correctly connected and are linked to the CNC control.
Fault in EMERGENCY Stop circuit
The Emergency Stop circuit has a 24V DC power supply like the other sensors. Check this control voltage
and the power supply. A cable may possibly be broken.
Emergency Stop button defective
One of the Emergency Stop button contacts (break contact) no longer closes correctly or is defective. It
may be that the contacts are no longer conducting (possibly because of oxidation).
In this case it is recommended that the contact set be inspected, and replaced if necessary
Defective off button on the control
The button is located on the front panel of the CNC control and is coloured red. By opening the front door,
it is possible to check the contact of this button.
Error 190 - 194 DOS error
DOS error 190
Diskette is write-protected.
DOS error 191
Drive not ready.
DOS error 194
Critical DOS error.

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Error 195 - x Photocell in cross-cut station obscured
Photocell for beginning of timber sends a signal
Check whether the optical axis of the photocell for beginning of timber recognition in the cross-cut station
is obscured by a piece of wood from a possible prior malfunction. Waste offcuts could also be responsible
for this error message. Before starting work, the cross-cut station must be completely cleared out.
Error / fault in the photocell for beginning of timber recognition
Check the signal from the photocell receiver via the terminal box on the cross-cut station to input
interface E1 on the CNC control. Check the cable connections and terminal clamps for possible loose
connections.
Wood has slipped in the cross-cut station
As soon as a board has been cut completely, the control checks to see whether the photocell for
beginning of timber recognition is free or whether the beginning of a new board has been registered. If this
is not the case, the above error message is displayed. If the board in the cross-cut station has slipped, the
fixed lengths will also be incorrect.
Incorrect measurement in measuring station

(the wood was measured too short)
If the wood in the measuring station was measured too short, it can happen that the photocell for
recognition of beginning of timber in the cross-cut station is still occupied by the wood end. The wood was
measured by the measuring station as being shorter than it actually is.
Error 197 - x Too many crayon lines
4 different cutting lists can be processed using the program changeover via code lines. To switch to
grade 4, 4 lines are marked on the board. If 5 lines between 10 mm and 30 mm apart are marked on the
board, the above error is reported.
Error 200-x Fifo full
Fifo full
Program internal storage (e.g. optimization results, event counters, ...) approaching overflow. Restart the
installation and consult the manufacturer.
Error 201-1 Number of cuts reached
The optimization storage memory is assigned a certain number of cuts per board. If this error message
appears, it is probably because the fixed lengths are too short for a too long board. Delete the too short
fixed lengths and consult the manufacturer.

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Error 203 – x Error of the photocell for beginning of timber recognition
or timber to short
The system checks at the photocell for beginning of timber recognition in the cross-cut station whether the
timber lengths are realistic. If a measured wood length is less than 30 cm, then the above error message
is displayed.
Possible causes:
Timber too thin or uneven
Badly adjusted photocell
Trim cut / last cut set too large
Make quite sure that even thin, crooked and also warped timber is detected perfectly by the photocell. If
this is not possible with a suitable photocell setting, an appropriate sensor must be used.
Dust clouds / offcuts in front of the photocell
Make sure that the optical axis between the transmitter and the receiver is free from contamination. If
large quantities of dust accumulate in this area , then the dust extraction power at the cross-cut station
must be increased.
Photocell malfunction
Check the functioning of the photocell from the receiver via the terminal box on the cross-cut station to
input interface E1 in the CNC control. Check all cable and terminal connections for possible loose
contacts.
Error 207 - 80 Saw rocker does not rise
Possible causes:
The lifting (cutting) time is set too short
Check the value set under lifting time. If this is set too low, the solenoid valve for the cutting stroke is only
activated very briefly. The saw rocker can not move upwards.
The throttle valves are set incorrectly or are contaminated
The exhaust air throttles near the saw lifting cylinder must be set so that the saw rocker moves upwards
during the triggering of the solenoid valve by the CNC control.
Error / Fault in ”Saw down” proximity switch
Error in control circuit for the ”Saw up” solenoid valve
The solenoid valve for the saw lift is triggered by a control voltage of about 30V DC. The trigger occurs via
the semiconductor relay fitted to the output board A1. Check the functioning of this relay, and the control
voltage from the relay to the solenoid valve. The status of this relay can be detected by means of the red
LED built into this board.
Defective solenoid valve

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Error 208 - 1 / 206 - x Saw rocker not in down position
Error / Fault in ”Saw down” proximity switch
Error in control circuit for the ”Saw up” solenoid valve
Defective solenoid valve
Error / Fault in lifting cylinder
Error 209 No lengths in the cutting list

The optimization program cannot find any lengths in the cutting list, or all piece counters are at zero.
Error 217 -1 No compressed air
Possible causes:
- Air pressure too low at pressure switch
- Broken cable / no connection between pressure switch and CNC control
- Faulty pressure switch
- Faulty input interface
Error 222 - x Cutting list full
The permissible number of pieces per program has been reached.
Error 999 - x axis parameter incorrect
The program has detected an illogical or illegal axis parameter setting and corrected it to sensible values.
Error 213-2 Sorting buffer full
The maximum number of pieces to be sorted has been reached. Apparently no data is read out from the
buffer. Please check the photocell and encoder on the sorting unit for their correct function.
Error 214-1 Sorting alarm
The reasonability check has detected an illogical sequence of the cut pieces to be sorted. Please delete
the buffer.

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2.7 Operating modes
Various operating modes can be selected, which have the following significance:
Mode Function
00 always attempts to cut the greatest possible fixed length,

the fixed lengths are not counted
02 always attempts to cut the greatest possible fixed length

and also counts the fixed lengths cut
40 as for 00, but makes an automatic trim cut
42 makes an automatic trim cut, counts the fixed lengths,

always attempts to cut the greatest possible fixed length
2.8 Operation of the partial optimization program
The machine always attempts to cut the greatest fixed length entered. This continues until either a board
end or a crayon line occurs. The control then decides, on the basis of several criteria, what is to be cut.
The criteria can be arbitrarily preselected and changed at any time.
They are, in detail:

a) the maximum permissible length of waste
b) the minimum remaining length that can still be used, e.g.

for finger jointing or for use at a later time
If then there comes a crayon line or the end of a board, it is checked:
1. whether the waste that remains is shorter than the maximum permissible waste length. If this condition
is fulfilled, then the greatest possible fixed length is cut. What happens to the remaining waste is
decided in accordance with the following criteria. If it is shorter than the minimum reusable remaining
ength, it is cut up for firewood. The length of the firewood can also be preselected. If the waste piece is
longer than the still usable remaining length, then it will not be cut up. If the firewood length is set to 0
mm, then the waste piece remains in one piece.
2. If the remainder that would follow the longest possible fixed length was longer than the maximum
permissible waste length, then a check is made as to whether it is also longer than the minimum
reusable remaining length. If this is so, then this fixed length and the reusable remaining length are cut.
If this is not the case, then a smaller fixed length is looked for, which would leave a sufficiently long
remainder. If no such fixed length is found, then the whole piece stays as one piece.

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Example:
Minimum reusable remaining length = 350 mm

maximum permissible waste length = 200 mm
Fixed lengths: 500 mm

1200 mm
1600 mm
Clear length = 1450 mm
1450 mm
- 1200 mm The computer attempts to cut the greatest possible fixed length.
________
= 250 mm This remaining piece is longer than the maximum permissible waste
and less than the minimum reusable remaining length.
1450 mm
- 350 mm The min. reusable remaining length is subtracted from
_________
= 1100 mm the clear length available and the remaining piece
is divided into two fixed lengths.
> 2 x 500 mm
1450 mm These two fixed lengths are now subtracted from the initial length.
- 500 mm The remaining piece meets the requirements for minimum
- 500 mm reusable remaining length and is moved out of the machine in one
________ piece.
= 450 mm
3. If only finger-joint lengths are required to be cut, then a very long fixed length e.g. 6000 mm is to be
entered. The minimum reusable remaining length is to be set to the minimum length the finger jointer
can handle, and the maximum permissible waste length can be set to any size
If there is a limit to the length of timber that can be handled by the finger jointer, then this length is to
be entered instead of the 6000 mm referred to above.

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2.9 System parameters
Some other sizes / parameters, that never, or very seldom, have to be changed, are stored in the system
parameters.
Important!
Changes to the default settings should only be made by trained specialist personnel or
after consultation with the manufacturer.
Before the system parameters are changed, their original values should be noted down.
Entering or checking the system parameter:

You can get to the system parameters by simultaneously pressing the <1> key and the <entry> key.
The machine stops, and setup

a: 200 (= Address) appears on the display
The <prog (ru)> key can be used to switch to the next parameter.
Entering new values
1. Press the <n> key

2. Enter new parameter value
3. Close with the <enter> key
If you enter an incorrect value -err- (Error / Error) is displayed
The addresses can also be selected directly. To do this the trim key (adr) is pressed, and the required
address is then entered. To close, the <enter> key is pressed again. The content is now displayed. If it
needs to be changed, proceed again as above.
If an invalid address is selected, the parameter value: --- is displayed
Exit the system parameters with the <mode> key.

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2.10 System parameters (values)
Address Value Comment Standard
-------------------------------------------------------------------------------------------------------------------------------------------
101 Feed drive acceleration 20 m/sec2
102 Feed speed deceleration 20 m/sec2
103 Speed forwards 333 (3.33 m/sec)
104 Speed backwards 333 (3.33 m/sec)
105 ks 4
106 kv 91
107 Offset 0
109 Speed for reference travel 150 (1.50 m/sec)
110 Permissible deviation 2
-------------------------------------------------------------------------------------------------------------------------------------------
202 Blow time in 1/100 sec 30 (0.30 sec)
203 Saw kerf 5 mm
204 Saw lifting time in 1/100 sec 30 (0.30 sec)
205 Mode 42
207 Distance photocell --> saw blade in mm
210 Trim cut 20 mm
212 Minimum finger-joint length 350 mm
214 Maximum permissible waste length 6000 mm
216 Firewood length 150 mm
218 Correction factor sign (0 = + * 1 = -)
219 Correction factor (10000 = 1.0000) cross-cut station
220 Part. feed before long length 240 mm
222 Waiting time after part. feed in 1/100 sec 50 (0.50 sec)
224 Maximum finger-joint length 2500
227 Minimum length for part. feed in mm 6000 mm
229 Min. long waste 500 mm
231 Hold-down (0 = OFF * 1 = ON)

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-------------------------------------------------------------------------------------------------------------------------------------------
232 Waiting time before blowing 1/100 sec 50 (0.50 sec)
233 Push out short length 0 mm
234 Push size 240 mm
235 End trimming of FJ lengths (0 = OFF * 1 = ON) 1
236 1st Roller up / down (0 = OFF * 1 = ON) 0
237 Line-code changeover (0 = OFF * 1 = ON) 0
238 Offset luminescent scanner in mm
239 Correction factor sign (0 = + * 1 = -) Measuring station
240 Correction factor (10000 = 1.0000) Measuring station
241 Display status 0
242 Trailing end trim cut 20 mm
243 Maximum long waste 1000 mm
244 Maximum firewood length 180 mm
245 Bad wood 240 mm
246 Crayon mark recognition on/off (0 = OFF * 1 = ON)
247 Waiting time until hold-down down
248 ...
249 ...
250 Special function

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2.11 Parameters of Sorting System

_____________________________________________________________________________
300 Sorting station for long waste 4

301 Sorting modes: 1 = without reasonability check
2 = with reasonability check
3 = with reasonability check
and self-help
302 Sorting pulse length
1930 mm/pulse
303 Sorting tolerance
25 %
304 Ejection time 15 (0.15sec)
305 Distance photocell-saw
7000 mm
306 Sorting station FJ lengths progr. 1/prog. 9
307 Sorting station FJ lengths progr. 2
310 Station 1 1000 mm
311 Mode Station 1 1

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2.12 Meaning of the system parameters
Set & test axis parameters
Important!
To set / change these parameters a fundamental knowledge of control engineering and
also of the whole feed system is required. Changes should only be made by service
technicians or under instructions from the manufacturer. Under certain circumstances
incorrect settings can entail danger to life and limb.
101 Acceleration acc:

102 Deceleration dec:
These parameters are used to set the acceleration / deceleration of the feed drive in m/s2. The values are
factory set. A reduction in acceleration can, in certain circumstances, give improved length accuracy.
103 max. speed back. v+:

104 max. speed forw v-:
This is the maximum feed speed at which a piece of wood can travel during processing. The factory-set
values are the maximum values achievable. A speed reduction can be useful to match the cross-cut feed
system to a slower operating cycle of a preceding machine.
105 ks ks:
This is the amplification factor of the control loop. For initial operation and for determining the axis
parameters, this factor should be set as low as possible ("1").
Important!
If the value of ks is set to zero, correct control response and the setting of control
parameters is no longer possible. The minimum setting for this value is 1!!!
Once the parameters have been set, this value should be so increased that the respective feed axis runs
and positions perfectly, but has no tendency to oscillate. An increased ks value makes the control stiffer,
but also the system’s tendency to oscillate.
106 kv kv:
After the data for the forwards / backwards speed has been set, these parameters must be changed until
the target voltage value of the feed axis in question is 8.3 V DC. In this case the speed controller is also to
be set to a target value of 8.3V DC at rated motor speed.
107 Offset offset:

Any possible drift behaviour which might occur in the feed axis can be eliminated by means of the Offset.
In principle the setting of this value has the same function as the "Drift / Offset" potentiometer on the
speed controller.
109 Speed Ref.-Pos. vref:

The value entered here defines the infeed speed of the incoming wood via the measuring station to the
cross-cut station.
110 perm. deviation delta:

This parameter defines the accuracy of the cutting release.

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202 Blow time
This is the time for which the blower is activated, if waste pieces or firewood have to be blown out after
cutting. The time is set on the basis of appropriate experience. Large wood cross-sections require a long
blowing time. Too short blowing times can result in malfunctions due to poorly disposed of offcuts. The
blown out firewood pieces must be carried away immediately without any trouble or obstruction, to prevent
congestion.
When blowing out waste pieces the appropriate top rollers are pneumatically raised as required. Make
quite sure that the rollers are raised from waste pieces as quickly as possible, so the waste pieces can be
blown out.
203 Saw kerf
The width of the saw cut is set here in millimetres.
The setting can also be used for correcting firm / constant ( length independent) length inaccuracies or
required plus or minus tolerances.
204 Lifting time
This is the opening time of the saw lift valve. The effective lifting time and the actual saw stroke result
from the adjustment of the valves on the machine. Make absolutely certain when setting the two speed
regulating valves (near the saw lift cylinder), that the saw rocker does not knock against the upper rubber
buffer when rising. This only serves as an end stop during short-term faulty settings. Continuous knocking
could lead to its destruction.
The saw rocker should come to the stop position absolutely smoothly when descending.
For a rapid and correct saw stroke it is important that the necessary compressed air is available in
sufficient quantities and at a defined minimum pressure. Large compressed air fluctuations impair the
efficiency of the saw installation.
Note that with a very fast-set saw lift and the use of soft wood more or less severe chips can occur at the
saw cut. The remedy for this is to reduce the saw lifting speed and /or the use of a different tool (saw
blade).
205 Mode
See chapter: Operating modes

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207 Distance photocell -> saw blade
The distance from the saw blade to the photocell for beginning of timber recognition in the cross-cut
station is set here. This is so to speak the reference point from board start to sawing position.
If the trim cut is too short (long) and / or the cut takes place before (after) the crayon lines then this value
should be increased (decreased).
The decisive criterion for the setting of this value should therefore be the accuracy of the preset 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 cut is only 25 mm long.
Depending on the type of cross-cut station, two photocell systems can be built in. The photocell which is
located closer to the sawing position / saw blade is responsible for the Photocell -> Saw distance. The first
photocell is generally for driving the solenoid valves of the first top roller.
210 Leading end trim cut

242 Trailing end trim cut
This is the size which is used to make a clean cut at the beginning of the board. Its accuracy is limited to a
measurement of some 5 mm depending on the nature of the wood.
The effective trim cut is the preset trim cut size minus the saw blade thickness.
Example: Trim cut = 30 mm
Saw blade thickness = 5 mm
This results in a trim cut piece of 30 mm minus 5 mm = 25 mm long.
Important!
If you want to work without a trim cut (trim cut = 0mm), then the first fixed length can in
certain circumstances vary more or less greatly. It is therefore recommended that an
appropriately large trim cut is set depending on the nature of the wood.
212 Min. finger-joint length

224 Max. finger-joint length
If no finger-joint lengths are to be produced, then the parameter for the minimum finger-joint length is to
be set greater than the smallest programmed fixed length. In this case only fixed lengths (and offcuts) are
produced.
Important!
The max. finger-joint length must be set at least twice as long as the min. finger-joint
length.
When exceeding the maximum finger-joint length, this piece is so apportioned that one piece with the
minimum finger-joint length is produced.
Example: min. finger-joint length = 500 mm

max. finger-joint length = 1500 mm
Based on the crayon lines on the wood, and the cutting list or parameter settings a finger-joint piece is
produced of 1760 mm overall. According to the above finger-joint limits this results in two finger-joint
pieces of 500 mm and 1260 mm.

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214 Max. permissible waste
If there is a remainder, after optimization, that exceeds the maximum permissible waste, then a
combination is formed that leaves a remainder of at least the size of the min. finger-joint length.
Example: programmed fixed length = 1000 mm

total input length = 1200 mm
Front = rear end trim cut = 20 mm
maximum permissible waste = 5000mm (normal case)

-> 1000mm (Fixed length) + 155mm (waste)
maximum permissible waste = 50mm

-> 1160mm (finger-joint length)
By decreasing the value for the max. perm. waste, the production of finger-joint lengths is increased and
the waste is reduced.
216 Minimum firewood length

244 Maximum firewood length
This is the max. length to which offcuts are shortened and blown out, if they are shorter than the min. long
waste.
Ensure that the firewood length is not set too large. Waste pieces may otherwise get jammed when being
blown out. To prevent unnecessary friction (-> high blowing time) of the waste pieces on the saw blade
cover, this should be cleaned in accordance with the amount of dirt produced.
The blowing time should be set in accordance with the firewood length and the wood cross-section so that
the waste pieces are blown out safely.
218 & 219 Saw correction factor

Due to the different surface forms (smooth, rough ..) and hardness of the wood, reproducible inaccuracies
of the measuring system in the cross-cut station can be compensated for in this way.
According to experience, soft wood for example is measured rather too short because the bottom rollers
press deeper into the workpiece than they do with hard wood.
This parameter is only then successful when it is a matter of linear length inaccuracies. If this is not the
case, i.e. if there is a random variation in the cut lengths, then this can possibly be traced back to friction
in the wood transport. The correction factor is of no help here.
If the fixed lengths are too short on average by e.g. 0.15%, then the correction factor must be increased
by 0.15%. To set the appropriate correction factor, you should carry out various tests with your smallest
and largest fixed lengths. The value to be entered can be the calculated average of the tests.
Note: If the measurement error is constant, i.e. independent of the length,

this can be better corrected with a different saw kerf setting.

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220 partial feed before a long length
222 Waiting time after partial feed
227 min. length for partial feed
If the cut pieces are to be separated after the machine, or the machine is too quick for some reason, a
feed stop can be set. The control can be programmed so that the stop is only made from a specific
Minimum length.
Before waiting, a short distance forward is travelled (partial feed) to ensure that previously cut wood is
lying loose on the outfeed conveyor.
The duration of the stop can be set with the Waiting time.
229 Min. long waste

243 Max. long waste
The minimum long waste ensures that long waste pieces, which are longer than this size, are not cut up
for firewood, but rather run out of the machine as one piece.
By reducing this value and so preventing many firewood lengths in the case of long waste pieces, the
output capacity of the machine can be increased.
If you don’t want to have any waste pieces on the outfeed side, then this value should be set very large
(e.g. 2000mm). In this way all waste pieces are cut into firewood.
When processing poor quality woods, very long continuous waste pieces can occur.
Important!
The max. long waste must be set at least twice as long as the min. long wastet!
When exceeding the maximum long waste, this piece is so apportioned that at least one piece with the
minimum long waste length is produced.
231 Hold-down (clamping device) on/off
Only on cross-cut systems in model series 11 !!!
Model 11 cross-cut systems can be equipped with a hold-down, if the shortest lengths to be sawn are
shorter than 230mm. If the hold-down is switched on, it only comes into action at board ends and with
short fixed or finger-joint lengths.
232 Waiting time before blowing
In order to be sure that the rollers have lifted from the wood, so that the waste pieces can be blown out
freely, a small waiting time can be inserted before the blower is activated.

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233 Push out short length
234 Push size
If very short lengths are to be cut and sorted, the preceding length must be pushed out of the machine
before the cut, so that during the cut a gap can occur for the plausibility test at the sorting unit.
All lengths which are shorter than the set size for push out short length (and which are not firewood) are
pushed before the cut by at least the size to be set here. The return movement to the length to be cut and
the cut itself take place immediately after.
This size is usually about a few centimeters greater than the distance between the saw blade and the last
roller pair. (e.g. 240 mm)
235 End trimming of finger-joint lengths
If a finger-joint length occurs at the end of a board, a final cut is made using the ”End trimming of finger-
joint lengths” operating mode.
With the ”No trimming of finger-joint lengths” setting, a final cut is not carried out.
236 1st Roller up/down
Normally there is a total of two photocells, consisting of a transmitter and a receiver, built into the cross-
cut station. The first photocell is for driving the solenoid valves of the first top roller. With this operating
mode the control of this top roller can be switched on or off.
Because of the high feed speed this top roller is not actually moved up and down. Only the upper cylinder
space is supplied with compressed air if this function is active and the light beam of the photocell is
interrupted.
If the above operating mode is switched off, the relay in the CNC control and also the solenoid valve in the
cross-cut station are always picked up. The compressed air cylinder is accordingly always supplied with
compressed air. This function can be switched off if the incoming wood has no thickness variations and is
not bent or warped.
237 Line-code changeover ON/OFF
With the line-code changeover switched ON several successive narrow crayon lines can be used to
identify the different qualities / cutting lists. The number of lines therefore equates to the quality / cutting
list. The nominal distance between lines is 20mm with a tolerance of ± 10mm.
The board front is also treated as a crayon line. Thus, when the complete board is to be cut in the second
quality / cutting list, the board front is to be provided with a crayon line at a distance of 20mm ± 10mm.
If line-code changeover is switched on, short defects must be marked with a distance of at least 31mm, so
that the crayon lines are not interpreted as line-code changeover.

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238 Luminescent scanner offset
This is the distance between the switching point of the wood start / wood end photocell and the
luminescent scanner switching point. 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 beside the crayon lines.
The correlation with the distance Photocell -> Saw is complex, since also an incorrect setting there causes
cutting beside 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 to be marked with a straight, thin but obvious line at exactly 100 mm from the start. Ensure that
this line is marked as near at right angles as possible to the board edge.
Go to the Saw operating mode. Please set the saw stroke so that the board is only slightly slit but not
sawn through.
Place the marked board on the running infeed conveyor belt. Ensure that the machine is correctly set to
the appropriate wood thickness.
Remove the board from the cross-cut station and compare the slit with the crayon line. Any possible
discrepancy can be corrected using the above parameter.
Inaccuracies of 2 millimeters are within the measurement tolerance range and do not have to be
corrected.
Large deviations are corrected as follows:
If the measured length is too great by x millimetres, the ”Luminescent scanner offset” is increased by x
millimetres.
If the measured length is too small by x millimetres, the ”Luminescent scanner offset” is decreased by x
millimetres.
This test can be repeated frequently, to establish a mean size for the offset.
239 & 240 Correction factor meas. st.
Can be used to compensate for reproducible inaccuracies of the measuring system caused by the surface
and the hardness of the wood.
This parameter can only be successful if identical lengths are too short or too long by the same size, or if
linear length inaccuracies are being dealt with. If this is not the case, i.e. if there is a random variation in
the measured lengths, then this can possibly be traced back to friction in the wood transport. The
correction factor is of no help here.
If the input lengths are for example too short on average by e.g. 0.15%, then the correction factor must be
increased by 0.15%. To set the appropriate correction factor, you should carry out various tests with your
smallest and largest input lengths. The value to be entered can be the calculated average of the tests. Be
aware that even the weight of the wood can play a part in the measurement.
Rule: Increase (decrease) the correction factor by the %

by which the lengths are too short (too long).

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241 Display status
Since the display capacity on the LCD display is limited, but important information must be displayed for
analytical purposes, additional information can be displayed via the display status.
Status: 0 no additional display

1 lag error display
2 board length measured by measuring station
3 Target value display (uncorrected)
245 Bad wood
If a longer piece of wood is to be marked as waste, several crayon lines are to be made to prevent the
piece from being assessed as fixed length or finger-joint length. If 2 lines are applied at a distance shorter
than the size set here, the piece will be assessed as waste. The value should generally be set smaller
than the shortest fixed/finger-joint length.
246 Crayon mark recognition ON/OFF
This parameter allows to switch off the crayon mark recognition function.
300 Sorting station for long waste
In case a sorting unit is connected, this parameter is used to set at which sorting station long waste will be
ejected. Ensure that the sorting station in question is also mechanically capable of ejecting the longest
waste pieces that may occur.
301 Sorting station finger-joint lengths

It is possible to set three different sorting modes.
Mode 1:
The cut pieces will be sorted in the order as they were cut without any reasonability check being made.
Mode 2:
The cut pieces will be sorted in the order as they were cut whilst a reasonability check takes place which
monitors the sorting order and generates a sorting alarm if anything appears illogical.
Mode 3:
The cut pieces will be sorted in the order as they were cut including reasonability check, i.e. monitoring of
the sorting order. However, before a sorting alarm comes up the system attempts to correct the apparently
mixed up sorting order. If unsuccessful, a sorting alarm will be issued on the next piece.

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302 Sorting pulse length
The sorting unit has an encoder for measuring the timber length (also see Sorting measurement
tolerance) and the ejection position. This encoder is generally a proximity switch which detects the
teeth/pulses of a chain sprocket on the drive unit of the first sorting belt and transmits them to the CNC
control. The tooth pitch of the sprocket equates to the pulse length.
To determine the pulse length, proceed as follows:
- Turn the sorting belt by hand until the associated LED on the input interface E2 just triggers.
- Mark the conveyor belt and the frame.
- Now turn the sorting belt again until the associated LED triggers again.
- The distance between the marking on the belt and the marking on the conveyor equals the pulse
length.
- Repeat this process three times to confirm the result.
Among other things a correctly adjusted pulse length is essential to ensure the ejection accuracy of the
sorting stations and to prevent a possible sorting alarm.
303 Sorting tolerance
The sorting equipment has a reasonability check function which re-measures the lengths and compares
them with the sequence of the cut lengths. If deviations occur, a sorting alarm is given and the feed
system of the cross-cut saw is stopped.
Since the measuring procedure for this check is relatively inaccurate, a certain measuring tolerance must
be allowed, which is set here.
If the permissible tolerance is set very large, the risk of incorrect sorting increases. If it is set too small,
fault alarms can be produced in spite of correct sorting sequences.
If you are working with a cutting list with relatively large (small) differences between the individual fixed
lengths, this parameter can be set accordingly high (low).
304 Ejection time

Only applicable if a length sorting equipment is connected.
The ejection time is the operating time of the relay contacts on the relay board or the opening time of the
valves for the ejection stations on a sorting equipment.
If the ejection time is set too short, the workpieces will not be ejected completely.
If it is set too long there is a risk of collision between the ejector and the following workpieces. This is
particularly detrimental if the sorting belt is run at a high speed.
Set the ejection time in such a way that your timber is still pushed off the sorting belt reliably, but with the
shortest possible ejection time.

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305 Distance photocell - saw
The distance from the cross-cut station to the photocell on the sorting unit is set here.
This function allows to sort cut lengths that are longer than the distance between cross-cut station and
photocell on the sorting unit.
310 Station 1
312 2
314 3
316 4
318 5
320 6
322 7
324 8
326 9
311 Mode Station 1

313 2
315 3
317 4
319 5
321 6
323 7
325 8
327 9
306 Sorting station FJ lengths progr. 1 / progr. 3

The sorting station for finger-joint lengths (reusable remainders) is set here.
In principle, any sorting station of the sorting unit can be used for this purpose. When programming,
however, take care to ensure that the sorting station concerned is also mechanically capable of ejecting
the complete range of your finger-joint lengths perfectly.

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2.13 Sorting stations
The respective ejector of a specific sorting station is located at a defined distance from the photocell at the
start of the sorting unit. The photocell represents so to speak the reference point for the sorting
stations/ejectors.
To keep the sorting system as flexible as possible, the distances between the individual ejectors and the
photocell can be set by means of this menu. If you want to install an ejector in another position, this
distance must be adapted to the new mechanical conditions.
There are three different ways (modes) of ejecting the fixed lengths with the aid of a sorting unit:
- leading edges flush = Mode 1

- centered = Mode 2
- trailing edges flush = Mode 3
Mode 1
Mode 2
Mode 3
Generally the ejectors are programmed so that the work pieces are ejected from the sorting belt centrally.
The figures behind the word "sorting station" refer to the associated relay on the relay board in the CNC
control. It is also possible (if requested) that the sequence of the ejectors does not completely correspond
to the sequence of the station numbers.
Sorting station 1 = Relay R1

... ...
... ...
Sorting station 9 = Relay R16

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2.14 Special functions
■ By pressing the <1> key and ENTER you go to the system parameters (see above).
■ By pressing the <2> key and ENTER the parameters are returned to the default settings. (Display
message: done! )
■ By pressing the <3> key and ENTER all cutting lists are cleared.
(Display message: killed_all! )
■ By pressing the <4> key and ENTER you go into a monitor operating mode that allows input signals to
be displayed or output signals to be switched. (Set/reset outputs with keys 1 - 8)
a. out0: shows the Run-Control (RC) output port

h. out1_l: shows the output port for relays 1-8
i. out1_h: shows the output port for relays 9-16
d. in1_l: shows the input port for inputs 1-8
e. in1_h: shows the input port for inputs 9-16
f. in2_l: shows the input port for inputs 17-24
g. in2_h: shows the input port for inputs 25-32
h. counter axis 0
i. counter axis 1
By pressing the <7> key and ENTER you go to the printer program. With a printer connected, you can
actuate the following functions:
1 print program = Press the <1> key to print the programs (cutting lists)
2 print parameter = Press the <2> key to print the parameters
By pressing the <8> key and ENTER it is possible to save values from the computer to diskette.
1 save program = Press the <1> key to save the programs (cutting lists) from the computer to
diskette
2 save parameter = Press the <2> key to save the parameters from the computer to diskette
By pressing the <9> key and ENTER it is possible to load values from diskette into the computer
1 load program = Press the <1> key to load the programs (cutting lists) from diskette into the
computer
2 load parameter = Press the <2> key to load the parameter from diskette into the computer

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3 Malfunctions and trouble-shooting
3.1 General
If malfunctions occur, it is vitally important firstly to check most accurately which functions are working
correctly and which are not. You must therefore be familiar with all the machine functions. Give us an error
description that is as exact as possible and accurately observed. Only thus can we help you as quickly as
possibly to eliminate the malfunction that has occurred in the installation. In this connection, let us have
your machine type, the CNC control fitted, and if possible the machine serial number. This information can
be found in the Manual and on the nameplate on the cross-cut system. Incorrect diagnosis because of
inaccurate or incorrect details from you always cause irritation and avoidable costs (drop in production,
incorrect delivery of replacement parts, ...)
In spite of technology, critical and logical thinking is indispensable !!!
Let yourself be guided by the following considerations:
■ A computer malfunction is relatively unlikely, if only machine functions are illogical and the screen
reacts logically to operator inputs. Problems are usually to be looked for in the sensors, mechanical
equipment, faulty work piece transport or incorrect setting of values/operating modes.
■ Machine actions are generally dependent on a single output circuit of the control system but often on
several input circuits and control system settings.
■ The most important precondition for localising an incomprehensible action is the understanding of the
programmed sequence of operations.
Note: The error descriptions listed offer no guarantee of completeness.

They are being continuously updated on the basis of our experiences with clients and users of
cross-cut systems.
If necessary, request a current version of our operating instructions from your dealer or from the
manufacturer for your CNC control.

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3.2 Measuring station
Error: The measuring station measures the wood longer/shorter than it is.
Incorrect correction value set.
If the measurement error increases with increasing wood length, i.e. is linear, then an incorrect parameter
setting of the correction value exists. Check these parameters (239 & 240) by means of the factory set
values.
Too much friction while measuring.
Possibly the wood you are processing is relatively bent and warped. If this is so, a certain inaccuracy must
be reckoned with.
Photocell(s) switching delay(s)
Check the photocells and their sequential circuit(s). Most faults occur in the receiver area.
FAULT: Crayon lines on the wood are not detected.
The luminescent scanner is set too low.
To increase the sensitivity of the luminescent scanner, you can adjust the intensity on a potentiometer. To
achieve a higher intensity, carefully rotate the potentiometer to the right with the help of a small
screwdriver.
The crayon line intensity is poor.
The crayon supplied with the cross-cut system was selected in accordance with particular factors and
guarantees safe operation. If you use a different crayon now, it can happen under certain circumstances
that the luminescent scanner would not detect this crayon, or not reliably.
The normal wax crayon does not mark very well on damp wood. For this purpose a crayon of a softer
construction can be used.
The luminescent scanner is incorrectly fitted.
The distance between the surface of the wood and the lens should approximately equate to the focal
length.
Fault in the control circuit.
The luminescent scanner has a 24V DC power supply, like the photocells. You can measure this power
supply in the terminal box on the cross-cut station using a voltage measuring device. To exclude a faulty
connecting cable between the terminal box and the luminescent scanner check the supply voltage at the
luminescent scanner.
Fault in the luminescent scanner.
Using a sheet of white paper, which is held in front of the switched on luminescent scanner, you can
detect the light spot of the UV lamp. If no light spot is seen, then the lamp is faulty or its effect is greatly
weakened.
If the luminescent scanner still has no reaction in spite of an applied control voltage of 24V DC and
operational lamp, it can be assumed that there is a fault in this scanner.

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Fault in the input interface board.
The luminescent scanner output signal with a voltage level of 24V DC is carried via a junction box to input
interface E1. The input signal can be displayed on this board by means of a green LED. Check whether
the appropriate LED on this board switches correctly.
Fault on the digi I/O card in the computer.
If you cannot establish any faults on the luminescent scanner or on the input interface, check the cable
connection between the interface board and the p.c. board in the computer.
FAULT: Line-code changeover (at board start) not working.
The ”Line-code changeover” operating mode is switched off
Check in the system parameters whether the line-code changeover is switched ON. This function is
normally only switched off when cutting is to be done with one cutting list.
The luminescent scanner is incorrectly mounted or the value for the offset of the luminescent
scanner is incorrect. (see system parameter 238)
The crayon line distance at board start is not accurate
This can cause problems especially with work pieces with oblique front edges. Since the board front is
also classified as a crayon line, the first crayon line must be located at a distance of some 20 mm from the
board front edge (tolerance: ± 10 mm).
FAULT: Not all crayon lines are detected.
Crayon lines are not correctly detected because of bends in the wood.
If you hold a sheet of white paper under the luminescent scanner, you will see a blue light spot. It is
precisely at this point that the crayon lines are detected. That means that all the crayon lines have to pass
by this point to be detected.
The intensity of the crayon line is poor.
See explanation / solution advice above.

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3.3 Cross-cut station
Fault: The wood is conveyed to the preset length,

but the saw does not rise.
The ”SAW” relay on A1 relay board picks up.
You can check the functioning of the semiconductor relay located on the A1 output board by means of a
red LED. If it lit, then the relay has switched through.
If the relay picks up very briefly, the cutting time or the lifting time is possibly set too short. In addition,
check the opening of the two throttle valves on the right near the saw lift cylinder.
If increasing the lifting time or opening the speed regulating valves do not have the desired effect, then the
solenoid valve for the saw lift might also be faulty or be jammed. Using a screwdriver it is possible to
activate the saw lift valve mechanically in order to check for a possible fault in the pneumatic equipment.
In this way it is also possible to get a piston which might be stuck moving again.
If the above adjustments / checks have produced no improvement, perhaps the solenoid of the valve
could get no voltage or is completely defective. The control voltage sent from the semiconductor relay on
the A1 output card to the solenoid valve is about 28 - 32 V DC. Check the control voltage at the solenoid
valve plug and also on the A1 board with a voltmeter at a high-set lifting time.
The ”SAW” relay on the A1 relay board does not pick up.
In this case there could be a fault on the A1 board or on the so-called Run-Control board. Since trouble-
shooting on one of these boards requires an exact knowledge of their construction, we recommend that it
be replaced.
In each case, check whether the saw lifting relay can be switched manually.
FAULT: The cut fixed lengths are too short.
The length correction factor or the saw kerf is set incorrectly.
If this error is linear, i.e. the measured difference between long lengths is greater than for short lengths,
this can be eliminated by means of the saw correction factor.
Check also whether the saw kerf value is set correctly.
Too much friction in the cross-cut station.
Check whether the wood in the cross-cut station is stopped by extreme friction. In this case the wood
cannot go along correctly at the high acceleration / speed of the feed drive and is possibly making brief
stops.
The top roller segments are unevenly worn.
Ensure that the top rollers are correctly adjusted for the thickness of the wood in accordance with the
graduated scale. Over time the top roller polyurethane rings wear unevenly. This wear can be equalised
again by turning the piston rods on the upper compressed air cylinders. The top rollers should be
absolutely parallel to the lower rollers. Since the measurement scale is calibrated on the condition of the
rings when new, a certain offset must be deducted for wear. The rings should be replaced after hard wear.

Phone: +49 (0)7371 / 500-0 Fax: +49 (0)7371 / 500-111 en B 736.02/1
FAULT: The cut fixed lengths are too long.
The length correction factor or the saw kerf is set incorrectly.
If this error is linear, i.e. the measured difference between long lengths is greater than for short lengths,
this can be eliminated by means of the saw correction factor.
Check also whether the saw kerf value is set correctly.
The rotary encoder drive at the cross-cut station is faulty.
The encoder at the cross-cut station informs the CNC control of the exact position of the wood. The
encoder is driven via a small toothed belt. Check whether this toothed belt is correctly tensioned and is
driving the encoder correctly. Check also that the toothed belt pulley is absolutely firmly connected to the
encoder axle.
Fault in the rotary encoder - interface board.
A so-called encoder interface is required to relay the incoming rotary encoder signals to the computer.
This board is also located in the CNC control. Check the incoming signals from the rotary encoder.
Fault in the rotary encoder.
If the 5V DC voltage supply to the rotary encoder is in order, but this sensor does not output the signal
correctly, then there is a fault in this component. In this case, complete replacement of the rotary encoder
is recommended.
FAULT: The trim cut or the first length is too short.
The distance photocell -> saw blade parameter is set incorrectly.
The distance from the wood beginning detecting photocell in the cross-cut station to the saw blade is an
important machine-specific parameter. Check whether the value of distance Photocell -> Saw is set
correctly in accordance with the factory settings. If this photocell has been exchanged, a different value
may be required for it.
The trim cut value is set to "0"
If you want to work without a trim cut (trim cut = 0mm), then the first fixed length can in certain
circumstances vary more or less greatly. It is therefore recommended that an appropriately large trim cut
is set depending on the nature of the wood.
The wood slides with friction in the cross-cut station or on the infeed conveyor.
Try to eliminate all the friction points both in the cross-cut station and on the infeed conveyor. The lower
fence on the infeed belt / roller conveyor must be in line with the fence in the cross-cut station. Check the
saw blade cover for possible signs of rubbing. If these are evident, the cover must be set deeper.
The top rollers / top roller pressure are set incorrectly.
Especially with warped wood, ensure that it is not held back briefly by a roller during feeding.

Phone: +49 (0)7371 / 500-0 Fax: +49 (0)7371 / 500-111 en B 736.02/1
FAULT: Cutting always takes place at a certain size beside the crayon line.
The distance photocell -> saw blade parameter is set incorrectly.
The distance from the wood beginning detecting photocell in the cross-cut station to the saw blade is an
important machine-specific parameter. Check whether the value of distance Photocell -> Saw is set
correctly in accordance with the factory settings. If this photocell has been exchanged, a different value
may be required for it.

Phone: +49 (0)7371 / 500-0 Fax: +49 (0)7371 / 500-111 en B 736.02/1
3.4 Feed system
The wood transport in the cross-cut station is effected by means of a high-capacity servomotor in
conjunction with the associated controller. This feed motor drives all the bottom rollers via a servo drive
and a special toothed belt.
FAULT: The cutting position is overrun during positioning. The feed has to move
the wood back.
Incorrect feed axis parameter setting.
Check the system parameters according to the factory settings.
Important!
To set / change these parameters a fundamental knowledge of control engineering and
also of the whole feed system is required. Changes should only be made by service
technicians or under instructions from the manufacturer. Under certain circumstances
incorrect settings can entail danger to life and limb.
Incorrect setting of the feed speed at the speed controller.
The feed speed set on the speed controller must agree with the mechanical data of the cross-cut system
and also the axis parameters. By rotating the tachopotentiometer the feed speed can be set appropriately.
In this connection, we would ask you, in your own best interests, to contact your dealer or the
manufacturer.
FAULT: The feed system starts to vibrate during wood transport or

positioning.
Incorrect feed axis parameter setting.
The gain of the speed controller is set too high.
The rotary encoder at the cross-cut station is defective or no longer works correctly.
FAULT: The feed drive constantly turns slowly (drifting).
Balance offset drift on feed controller
With the target value connector disconnected, the feed drive must stay completely still. If this is not the
case, the offset at the controller drift potentiometer must be balanced. To do this, use a small screwdriver
to turn the appropriate potentiometer to the right or left while simultaneously observing the feed
movement.
The rotary encoder signal line to the cross-cut station is interrupted or the plug-in connector is
disconnected.
Check the incoming signals from the rotary encoder. If no signals are arriving, there may be a fault in the
cable connection between the encoder, the interface card or at the encoder itself.

Phone: +49 (0)7371 / 500-0 Fax: +49 (0)7371 / 500-111 en B 736.02/1
3.5 Input signals
3.5.1 Inputs (Run - Control)

The Run - Control board input signals link the ”ON” and ”OFF” buttons and the EMERGENCY
OFF and interlock systems.
The following items are tested during the self-test:
Safety relay R98
This relay must have picked up, after the CNC control has loaded the program. Otherwise there is
a malfunction in the computer or the Run-Control board or the cable connections.
On button
If the ON button is pressed, the safety relay R99 picks up, passing the control voltage through to
the line contactor and the electrical control.
Emergency Off circuit
A check is made as to whether the Emergency Off circuit is closed. This means that all the
Emergency Off buttons located in the cross-cut station must be released and connected.
Interlock control circuit
There are various interlocks, hoods etc. on the cross-cut system, which must be closed during
operation. If this is not the case, the system cannot be started. If one of these interlocks is not
properly closed, an error message appears on the display.

Phone: +49 (0)7371 / 500-0 Fax: +49 (0)7371 / 500-111 en B 736.02/1
3.5.2 Input interface E1
The input signals are in the main limited to the following sensors:
-> Wood detecting photocell(s)

-> Proximity switches
-> Luminescent scanner (Model KE)
The sensors on the input interface are driven by a 24V DC supply. This voltage is generated by a
power supply unit located in the CNC control cabinet. In order to ensure a safe switching condition
on the input interface, the following voltage levels are to be observed:
Low - Signal < 5V DC

High- Signal > 15V DC
If the input signal lies within a voltage range of +5 V DC to +15 V DC, safe switching is no longer
guaranteed.
In order to be able to check the input signals relatively easily, there is an LED on the sensor, and
on the respective input of the input interface.
The assignment of the sensors to the input signal LED’s can be found in the valid electrical circuit
diagrams.
3.5.3 Rotary encoder inputs
The rotary encoder inputs go directly to the computer. The encoders have a total of 4 channels.
These are the two signals A and B and their inversion. In this way it is possible to transmit in
complete safety, even at the relatively low signal level of 5 VDC.

Phone: +49 (0)7371 / 500-0 Fax: +49 (0)7371 / 500-111 en B 736.02/1
3.6 Output signals
If when switching on the outputs the corresponding LED’s on the interface connection do not react, then
there is a fault in the computer or at the interface connection. Otherwise there is possibly a malfunction in
the electrical circuit (incl. relays on the output interface) to be found.
3.6.1 Outputs (Run - Control)

The Run - Control board outputs mainly control the semiconductor relay(s) on the output board
A1. Normally, the solenoid valve for the saw stroke is controlled by this semiconductor relay.
The safety relays R98 and R99 are also located on the Run - Control board.
3.6.2 Outputs (Cross-cut station)

The output signals to the cross-cut station solenoid valves are transmitted through the output
boards A1 and A2.
Output board A1:
Depending on the configuration of your cross-cut system, this board is fitted with one or two so-
called performance opto-couplers (semiconductor relays). These relays, as distinct from the
conventional relay with contacts, enable very rapid and accurate switching. On these grounds
these relays are also used in the rapid switching of solenoid valves, such as e.g. the saw lifting
valve in the cross-cut station. One of the LED’s assigned to the appropriate relay indicates the
switching status of the relay. LED = lit --> Relay is switched.
Note:
Although the saw lifting valve has a nominal voltage of 24V DC, this valve is controlled by a
voltage of about 28 - 32V DC so as to ensure rapid opening.
Output card A2:
This card is fitted with R8 relays, of which relays R7 and 8 are voltageless. The relay assignments
can be found in the appropriate switching documentation of your machine.
These relays switch the solenoid valves fitted to the cross-cut station with a control voltage of 24V.
The control voltage for this is produced in the switch cabinet of the cross-cut system.

Phone: +49 (0)7371 / 500-0 Fax: +49 (0)7371 / 500-111 en B 736.02/1
4 Special functions
4.1 Automatic sequence cutting program
By means of the auto sequence cutting program the boards can be cut in any preselectable order. The
program always selects the next pre-programmed fixed length independently. As soon as a board is taken
into the cross-cut saw, the first length is started. It is the complete boards and not the individual fixed
lengths that are counted. As soon as the counter reaches 0, the machine stops. If less cuts are
programmed than the length of the board, the remainder is either removed complete from the machine, or
is cut up into firewood.
Programming the cutting sequence
After the computer has booted up, the following display appears:
NCK-1 7490-1.00 (Example)
1. Press <prog> key

the display shows e.g. Display Prog.1
2. The sequence cutting function is activated with program 9

press the <9> key
the display shows: Display Prog.9
l xxxx n yyyy z
xxxx = fixed length in mm

yyyy = counter reading
z = serial number
3. If no fixed lengths are programmed, the display shows: Display Prog.9

-empty-
4. Press the <l> key

the display shows: set (9)
l
5. Enter required fixed length in mm and confirm with the <enter> key
6. Enter the required quantity and confirm with the <enter> key

Phone: +49 (0)7371 / 500-0 Fax: +49 (0)7371 / 500-111 en B 736.02/1
Programmed lengths display

2. The auto sequence cutting function is activated with program 9

Press the <9> key
l xxxx n yyyy z
xxxx = Fixed length in mm

yyyy = Counter reading
z = serial number

-empty-
4. By repeatedly pressing the <prog> key the programmed lengths can be viewed.
Delete individual lengths

2. The sequence cutting function is activated with program 9

Press the <9> key
l xxxx n yyyy z
xxxx = Fixed length in mm

yyyy = Counter reading
z = serial number

-empty-
4. By repeatedly pressing the <prog> key the programmed lengths can be viewed.
5. The displayed length can be deleted by pressing the <del> key
6. If the whole program storage memory is to be cleared, length 9999 is entered

Phone: +49 (0)7371 / 500-0 Fax: +49 (0)7371 / 500-111 en B 736.02/1
4.2 Length correction
Because of the different surface forms (smooth, rough ..) and hardness of the wood, the feed rollers
measure different lengths. For example soft wood is cut too short and hard wood too long. The length
correction program can be used to assist here.
This program can only be successful if identical lengths differ by the same amount. If this is not the case,
i.e. if there is a random variation in the cut lengths, then this is usually traced back to friction in the feed
system. Length correction is of no help here.
The correction program works in relation to the length concerned in tenths per thousand mm since the
measuring error is linear and will become larger the longer the wood.
Measuring the correction factor:

Set the correction factor to 0 and cut several similar pieces of wood with a length of at least 2 m. Measure
the cut lengths and calculate the correction data using the following formula.
programmed length - measured length

Correction factor = 10000 x ----------------------------------------------------
programmed length
Please use lengths in mm.
The correction factor and the sign are stored as system parameters. The addresses can be found in the
system parameters list.
The correct sign is automatically produced by the calculation. This is entered in coded form + = 00
and - = 01.
Example: programmed length = 1750 mm

measured length. = 1754 mm
giving the sign - = 01 and the correction factor = 22

Phone: +49 (0)7371 / 500-0 Fax: +49 (0)7371 / 500-111 en B 736.02/1

Operating Manual

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Operating Manual

Max-Paul-Straße 1 88525 Dürmentingen / Germany 02.06.1999 TR/MB/LM

1.1 Switching on the CNC control....................................................................................4

2 Operating the machine ..........................................................................................6

2.1 Automatic operating sequence..................................................................................6

3 Malfunctions and trouble-shooting ....................................................................33

Max-Paul-Straße 1 88525 Dürmentingen / Germany 02.06.1999 TR/MB/LM

3.6 Output signals ............................................................................................................42

4.1 Automatic sequence cutting program ....................................................................43

Max-Paul-Straße 1 88525 Dürmentingen / Germany 02.06.1999 TR/MB/LM

1.1 Switching on the CNC control

NCK-1 7490-1.08 NCK-1 = Name of CNC control

1.2 Switching on the cross-cut system

1.3 Entering lengths and numbers of pieces to be cut

1. Press the <l> key

3. Enter the number of pieces required

4. Confirm with the <enter> key

5. If another length is to be entered, follow points 1 - 4.

Max-Paul-Straße 1 88525 Dürmentingen / Germany 02.06.1999 TR/MB/LM

1.5 Entering the trim cut length

1.6 Entering the saw lifting (cutting) time

1.7 Checking the entered lengths and numbers of pieces to be cut

1.8 Changing a counter reading

1.9 Deleting a fixed length

Max-Paul-Straße 1 88525 Dürmentingen / Germany 02.06.1999 TR/MB/LM

2.1 Automatic operating sequence

Max-Paul-Straße 1 88525 Dürmentingen / Germany 02.06.1999 TR/MB/LM

1st. Display 2nd Display 3rd Display 4th Display

Target value in mm Actual value in mm Application Status

Application: 0 = Fixed length

Status: 1 = Feed runs at feeding-in speed

Max-Paul-Straße 1 88525 Dürmentingen / Germany 02.06.1999 TR/MB/LM

Max-Paul-Straße 1 88525 Dürmentingen / Germany 02.06.1999 TR/MB/LM

The corresponding error code is displayed for error messages.

Error 1-1 green start button not pressed

Error 2-1 Run - Control has tripped

Error 3-1 Protection device open

Error 4 -1 EMERGENCY-OFF button pressed

Error 190 - 194 DOS error

Error 195 - 60 no board end - photoelectric barrier in sawing station obscured

Error 197 - x too many crayon lines

Error 200 - x FIFO full

Error 201 - 1 Number of cuts reached (Optimisation)

Error 203 - x Wood too short

Error 207 - 80 Saw rocker not rising

Error 208 - 1 Saw rocker not in down position

Error 208 - 2 Photoelectric barrier in sawing station obscured

Error 209 no lengths in the cutting list

Error 206- x Saw not down

Error 222 - 1 Cutting list full (Program 1 - 4 max. 30 lengths)

Error 222 - 2 Cutting list full (Program 9 max. 10 lengths)

Error 217- 1 No compressed air

Error 999 - x Axis parameters incorrect

Error 213-2 Sorting buffer full

Error 214-1 Sorting alarm

Max-Paul-Straße 1 88525 Dürmentingen / Germany 02.06.1999 TR/MB/LM

Error 1 - 1 Start the installation with the green button

Error 3 - 1 Protection device open?

Other possible causes:

Limit switches on protection devices not (fully) closed.

Fault in the safety circuit

Defective limit switch