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Esko Kongsberg XL Service Manual Download Page 7

i-XL Service Guide 

 

7 

Currently, the FlexiHead and MultiCut tool heads are prepared for the i-Cut camera. 
 
You will find more details in chapter 5, 6 and 7. 
 

2.4

 

More vacuum sections 

 
Depending upon the model type, an i-XL table will have more vacuum sections compared to 
standard XL. 
 

2.5

 

Pressurized air supervision 

 
To avoid damage due to missing or too low air pressure, a sensor is located beneath the cutting 
table.  
If the pressure level for the pressurized air is below a certain limit, machine execution is stopped 
and an error message is displayed. The sensor is connected to the air tube for traverse and tool 
control. 
The input from the sensor is read by an analogue input on SCU. 
 

2.6

 

The conveyor belt (optional) 

 
The i-XL table can be equipped with a conveyor belt. With the conveyor belt, you can feed material 
into and out from the working area on the cutting table. 
The pulling force is approximately 400N. 
 

Adjustable

Adjustable

Adjustable  guides

 

 
The belt itself is a specially prepared conveyor belt. 
 
The picture above shows how the belt is moving around rollers mounted on both sides of the table 
and the table frame.  
One or more rollers inside the table frame prevent the belt from touching the floor. 
 
When shipped from Kongsberg, the belt is rolled up in a separate roll. During installation, you have 
to mount the belt onto the table and glue it together. You will find a detailed description on how to 
glue the belt in chapter 
 

Summary of Contents for Kongsberg XL

Page 1: ...s not indicate that this work has been published All rights strictly reserved Reproduction or issue to third parties in any form whatever is not permitted without written authority from the publisher Esko reserves the right to change specifications without notice Document number D3073 Status 110905 Esko Graphics Kongsberg AS www esko com P O Box 1016 N 3601 Kongsberg Norway Tel 47 32 28 99 00 Fax ...

Page 2: ...tial or incidental damages arising out of the use or inability to use the system or the information contained herein The information contained herein is subject to change without notice Revisions may be issued from time to time to advise of such changes and or additions No part of this system may be reproduced stored in a data base or retrieval system or published in any form or in any way electro...

Page 3: ... running i Cut 12 3 3 3 Execution 12 4 FLEXIHEAD WITH I CUT 13 5 MULTICUT WITH I CUT 13 6 I CUT CAMERA CONNECTION TO PC 14 7 I CUT CAMERA ADJUSTMENT 14 8 SOFTWARE INSTALLATION 15 8 1 INSTALL XL GUIDE 15 8 2 INSTALL I CUT HARDWARE AND SOFTWARE 15 8 3 HOW TO UPDATE THE I CUT LICENSE CODES 15 8 4 CONFIGURE XL GUIDE FOR I CUT CONTROL 16 8 5 CONFIGURE I CUT FOR THE KONGSBERG I XL 16 9 HOW TO CHECK CAME...

Page 4: ...MECHANICAL DRAWINGS 43 17 1 I XL20 W CONVEYOR 43 17 2 I XL20 W 2 VACUUM SECTIONS 43 17 3 I XL20 W 2 SECTIONS AND VACUUM REVERSE 43 17 4 I XL24 W CONVEYOR 43 17 5 I XL24 W 3 VACUUM SECTIONS 43 17 6 I XL24 W 3 SECTIONS AND VACUUM REVERSE 43 17 7 I XL44 W CONVEYOR 43 17 8 I XL44 W 3 VACUUM SECTIONS 43 17 9 I XL44 W 3 SECTIONS AND VACUUM REVERSE 43 18 APPENDIX 1 I CUT PRODUCTION SETTINGS FOR KONGSBERG...

Page 5: ...XL compared to XL What are the mechanical differences What are the electrical differences What about software How do I operate i XL The intention of this manual is to answer such questions It is aimed especially for Esko Graphics service personnel ...

Page 6: ... the i XL table frame close to the X Y corner of the table The i Cut computer stand includes the following components An XP pc delivered from Shuttle with keyboard and mouse The keyboard is a dedicated model built into the top of the stand A flat screen monitor for the pc A complete MCU unit including a standard XL operator panel The only difference is that the operator panel and the MCU unit are ...

Page 7: ...trol The input from the sensor is read by an analogue input on SCU 2 6 The conveyor belt optional The i XL table can be equipped with a conveyor belt With the conveyor belt you can feed material into and out from the working area on the cutting table The pulling force is approximately 400N Adjustable Adjustable Adjustable guides The belt itself is a specially prepared conveyor belt The picture abo...

Page 8: ... as i XL24 and i XL44 Two different air cylinder systems are used to grab the belt and move it forward Both systems are mounted onto the traverse as it is the traverse that actually moves the belt forward 2 6 1 The belt clamps One clamp on each side grabs the belt and moves it forward ...

Page 9: ...aximum pressure should be applied to the belt clamp The pressure to the feeder paws should be kept as low as possible as increased pressure increases the friction between the belt and the table 2 6 3 Vacuum reverse In order to minimize the friction between the conveyor belt and the cutting table an air blow is creating an air pillow below the belt during the belt movement Two vacuum valves and a f...

Page 10: ...mounted on the rear side of the cutting table You can load a stack of material into the sheet feeder The feeder will lift one and one sheet onto the cutting table where the conveyor belt system moves the material into the working area of the machine The interface between the sheet feeder and the i XL table is just one control signal In addition there is an USB connection between the sheet feeder a...

Page 11: ...he Init push button on the Operator panel The fixed reference point number 1 is defined to be the Main reference point The Main reference point has to be correctly positioned in order to obtain A full working area Correct sheet feed operation Correct handling of long jobs Using the Main reference point during program execution ensures correct operation 3 2 Set the Main reference point for i Cut If...

Page 12: ...ow these rules 1 The Main reference point on the table Ref point 1 is set using the i Cut Main Reference button as described above Do not modify the position of Reference point 1 after this initial setting 2 As reference point when running XL Guide select any of the other reference points available for instance Reference point 2 Go to Option Table setup Set Reference point Select reference point 2...

Page 13: ...i XL Service Guide 13 4 FlexiHead with i Cut I Cut camera 5 MultiCut with i Cut I Cut camera ...

Page 14: ... supply provides power to the camera and the light unit 7 i Cut camera adjustment Two adjustments are available A adjust the aperture F adjust camera focus Note When adjusting the i Cut camera on MultiCut the adjustment knobs are available in between the knife foot as illustrated in the picture above Before any adjustments are carried out remove the knife from this tool position ...

Page 15: ...one for production preparation and one for cutting table control On the Front end PC the cutting table control dongle should be used 3 Connect the plotter and vision system to your computer 4 Log onto your Windows operating system administrator account 5 Insert the i Cut installation disc into your CD ROM compatible drive Installing i Cut requires adding the following three software components to ...

Page 16: ...options Set reference point Ref pt no 1 i Cut Main Reference Options Table options Set reference point Execute Single multiple design Main toolbar Single design 8 5 Configure i Cut for the Kongsberg i XL From PC Desktop or Start menu start i Cut Note After start up i Cut is waiting until the table zero sequence on the table is completed Therefore press Start to execute the sequence From the Option...

Page 17: ...L Guide is started 3 Switch servo on and complete the Table zero sequence 4 From the i Cut Calibration menu select Check Regmark 5 A window showing the camera picture appears Sometimes you have to open the window from the task bar Adjust the camera aperture and focus until you have a light picture with focus as sharp as possible ...

Page 18: ...t knife tool A complete kisscut tool consist of A The tool body B Knife adapter C Locking knob with Pressure unit 1 D Knife foot E Knife F Pressure unit 2 G Spanner The picture at left shows how to insert the knife into the knife adapter ...

Page 19: ...e from the adapter The picture shows the knife properly mounted Now the knife tool is ready to use The knife depth is controlled by knife pressure If you need exact control of knife depth use the knife foot as illustrated at left The depth is controlled by the foot position relative to the knife Turn the foot to adjust ...

Page 20: ...y turning the Pressure unit knob available on top of the KissCut tool Adjust and make a test cut to obtain correct setting If higher knife pressure is needed interchange Pressure units Pressure range Pressure unit 1 0 3 3 5 N Pressure unit 1 0 8 7 5 N ...

Page 21: ...rollers to be parallel to the tabletop Use the lower rollers for belt tension adjustment As the adjustment span is limited it is important you position the rollers in a middle position before gluing the belt Belt tension It is difficult to give an exact advice for belt tension The illustration at left shows that a relative high belt tension is recommended ...

Page 22: ... Belt glue procedure November 05 2007 Compared to the previous procedure this is a simplified method where the belt is cut at an angle and glued in one operation The cut angle and distances are found in this figure 1 i XE10 w 960 mm 37 8 inch 22 23o i XE32 w 1360 mm 53 5 inch i XL24 w 1740 mm 68 5 inch i XL4x w 2270 mm 89 4 inch 398 mm 16 inch 563 mm 22 inch 720 mm 28 inch 940 mm 37 inch ...

Page 23: ...ve to DP 110 A complete set is available as 02737781 Conveyor belt repair kit One glue tube with two nozzles is available as 02737872 Conveyor belt glue pack Assemble the glue applicator 1 Insert the plunger 2 Mount the glue tube 3 Remove the cap from the glue tube 4 Remove any sealing 5 Mount the nozzle 6 Purge the nozzle Note Use protective gloves when handling the glue Use safety glasses avoid ...

Page 24: ...rientation Move all rollers to the inner position before the belt is mounted In this way you have the possibility to increase the tension after mounting Roll out the belt onto the table The belt should not be too tight and not too loose The picture shows how the belt is hanging between the rolls beneath the table frame Put a sheet of material beneath the belt preparing for the knife cut Ensure cor...

Page 25: ...place a ruler along the cut path Use a sharp knife to cut through both belt materials Remove waste material and the cutting underlay 3 mm 1 8 inch Pull the belt parts apart until there is a gap of 3 mm 1 8 inch From the bottom and up apply a tape beneath the belt in order to Keep the belt together Prevent gluing the belt to the table top ...

Page 26: ... have a round top above the belt surface Note Use protective gloves when handling the glue Use safety glasses avoid any contact between glue and eyes Avoid direct contact or inhale of glue Make sure to discard the nozzle and replace the cap on your adhesive Apply tape on top of the glue By hand rub the surface of the tape until it is flat and even ...

Page 27: ...ce Add some heavy weight Wait minimum 2 hours for the adhesive to harden Remove the load and the tape If necessary sand the top of the adhesive until the surface is smooth and flat Pay special attention to the edges Ensure the belt edges are smooth and without sharp edges ...

Page 28: ...lt glue procedure 12 3 1 Tools you need 1 Milling motor 2 Milling bit square 4 mm see picture at left 3 Wrenches for the motor chuck 4 Holder for milling motor 5 Superglue 6 Glue gun for melted glue 7 Glue for glue gun 8 Sanding paper ...

Page 29: ...ation Roll out the belt onto the table The belt should not be tight The picture shows how the belt is hanging between the rolls beneath the table frame Mount the belt onto the cutting table with ends overlapping Ensure the belt is parallell to the table edges Use application tape to secure the belts position on the table Cut both ends of the conveyor belt in exactly 90o with a straight and clean c...

Page 30: ...i XL Service Guide 30 Use a straight ruler as a guide when cutting the two belt ends With adhesive tape fix one end of the belt Place an adhesive tape on the table with the adhesive side up as shown ...

Page 31: ...i XL Service Guide 31 Put half of the tape beneath the fixed belt end Fix the tape Pull the two belt ends together and fix them with the tape Use adhesive tape to keep the belt in position ...

Page 32: ...tant the centerstructure of the belt is kept undamaged Use the straight ruler as an aid when milling a path in the belt material The path should be centered on the belt edges Use a sanding paper to clean the path Use a vacuum cleaner to remove dust and particles from the path Use Super Glue to glue the two ends of the belt together The glue should flow down and fill the belt structure all way thro...

Page 33: ...se the Router once more to remove glue and prepare a clean path Use a vacuum cleaner to remove dust and particles from the path Fill the path with glue using a hot melt gun Use a flat and sharp knife to remove superflous glue ...

Page 34: ...L Service Guide 34 Use a sanding paper to smoothen the glue surface and make it even with the belt material around Pay special attention to the edges Ensure the belt edges are smooth and witout sharp edges ...

Page 35: ...n the PC and the Sheet feeder is 9600 baud 8 bit Odd parity No flow control 13 3 Sheet feeder setup Parameter sheet feeder panel Setting Horizontal Lift Jog Off Horizontal Lift Enable for Auto Yes if using Level Lift option No otherwise Horiz Lift Move Forward At Release Time 6 seconds i Cut Communication On Rollback Distance 15 mm Pick Pause Distance 25 mm Number of Pick Attempts 3 Drive Current ...

Page 36: ...ds Carriage Position 2 mm For optimising of performance to various materials etc adjustments might be required For description of each setting see Sheet Feeder Operators Manual 13 4 Sheet feeder Load table brackets These pictures show how to use the table brackets to create a container suitable for the stack of material ...

Page 37: ...i XL Service Guide 37 Picture at left To release the fixture push the locking pin Pictures below Mount the air knives in front of the stack of material in order to improve sheet separation ...

Page 38: ...ervice Guide 38 14 Air and vacuum blocked schematic 14 1 Pressurized air layout when sheet feeder is installed Sheet Feeder 12174447 12702205 12174413 From customer 42443002 42445742 Wall outlet Cutting table ...

Page 39: ... 1 5 5 1 2 B 4 A 4 A Belt Clamp Belt clamp on Feeder paws up Air Pressure Sensor Switch on when pressure 4 bar Foil feed To sheet feeder Vacuum sect 1 Front Vacuum pump Vacuum reverse 48V servo on controlled Vacuum sect 2 Vacuum area 1 Feeder paws down Feeder paws down Pressurized air 7 bar ...

Page 40: ...i XL Service Guide 40 14 3 Two vacuum pumps optional 14 3 1 General 14 3 2 3 sections 14 3 3 4 sections ...

Page 41: ...age outlet front view 1 2 12V 3 4 GND LED power 4 12V 1 GND 12V 0V Camera power 12 12V 11 GND C a m e r a Light Unit Foil Feed Start weeder Vacuum reverse Vacuum reverse Release sheet feeder Sheet feeder conn Glue Applicator FlexiHead Belt Clamp On Feeder Paws Down SCU DO 09 24V 0V 24V SCU DO 02 SCU DO 04 SCU DI 02 SCU DO 05 TCU DO 06 1 4 2 3 1 4 2 3 1 2 3 4 5 6 7 8 9 10 11 12 ...

Page 42: ... 16 1 2 Sheet feeder connections details 16 1 3 Pressurized air sensor details 16 1 4 i XL 20 cable overview 16 1 5 i XL 24 cable overview 16 1 6 i XL 44 cable overview 16 2 Sheet feeder 16 2 1 Power and safety relay 16 2 2 Motor drive wiring 16 2 3 PLC I O 16 2 4 I O 16 2 5 I O 16 2 6 Enclosure ...

Page 43: ...tions 404525 17 3 i XL20 w 2 sections and vacuum reverse 404290 17 4 i XL24 w conveyor 404445 17 5 i XL24 w 3 vacuum sections 404526 17 6 i XL24 w 3 sections and vacuum reverse 404435 17 7 i XL44 w conveyor 404515 17 8 i XL44 w 3 vacuum sections 404517 17 9 i XL44 w 3 sections and vacuum reverse 404513 ...

Page 44: ...or Kongsberg This is just one sample to show how to control vacuum and blow back in a manual operation setup I FM 0 1 Sheet feed communication PMPon off starts stops the vacuum pump SUCon off controls whether we have suction or blow back SUCoff blow back I PK park ...

Page 45: ...dden beneath the belt This procedure describes one method to verify and adjust the angle Cutting table Y X Put a sheet of material on the cutting table Switch vacuum on Keep the vacuum on during the execution of this procedure B Execute the following file found in the IAT directory i XE10 AngleCut10 acm i XL24 AngleCut24 acm i XL44 AngleCut44 acm Run with a knife and cut through the material While...

Page 46: ... of adjustment as illustrated at left use the two red spots as reference when executing the Angle adjust wizard B If the angle is out of adjustment the opposite way as illustrated at left use the two red spots as reference when executing the Angle adjust wizard B When the angle is correctly adjusted the two cuts should align ...

Page 47: ... 2 4 4 1 1 5 5 3 3 Press regulator Press regulator 2 B 1 5 5 1 2 B 4 A 4 A Belt Clamp Belt clamp on Feeder paws up Air Pressure Sensor Switch on when pressure 4 bar Foil feed To sheet feeder Vacuum sect 1 Front Vacuum pump Vacuum reverse 48V servo on controlled Vacuum sect 2 Vacuum area 1 Feeder paws down Feeder paws down Pressurized air 7 bar ...

Page 48: ...dicated 3 fix a string to the air tube 4 put the string through the traverse by pulling the air tube out 5 Fix the two additional cables together with the air tube to the string 6 Pull the string and drag the cables and the air tube into the traverse beam 7 suddenly you have both the air tube and the cables in place For some pictures see next page ...

Page 49: ...i XL Service Guide 49 String fixed to the air tube Pull the air tube out in order to pull the string through the traverse beam Fix cables to the string Ready to be pulled into the traverse beam ...

Page 50: ...i XL Service Guide 50 Pull the string to move the cables into the traverse ...

Page 51: ...i XL Service Guide 51 20 3 Rear side of traverse assembly View nearest to X2 end of traverse ...

Page 52: ...i XL Service Guide 52 View nearest to X1 end of traverse ...

Page 53: ...i XL Service Guide 53 20 4 Feeder clamp X1 assembly 20 5 Feeder clamp X2 assembly ...

Page 54: ...n assembly procedure If not available drill the fixture holes in the frame beam D L W Fixture hole information L 120 mm 4 72 inches W 258 mm 10 16 inches D 2 x ø9 0 mm 0 35 inches Assemble the frame bracket as shown at left Fix the frame bracket to the frame ...

Page 55: ...t sub assembly is the pc housing The picture shows the parts included Insert the screws as shown Mount the side brackets to the housing The side brackets should align with the top of the pc housing Fix the brackets in this position ...

Page 56: ...perator panel keyboard screen mouse ON OFF switch and Emergency stop switch in between the side brackets Ensure you have all cables in place before continuing If you miss one you have to repeat from here Mount the foot onto the beam as shown In the upper right corner picture you see the T slot nut Insert two nuts into the slots in the beam ...

Page 57: ...ards the pc housing and fix it using one T slot nut entered from above Ensure the beam is exactly vertical If not loosen the T slot nut carefully and adjust the beam until perfect Then fix the beam to the pc housing using all four T slot nuts ...

Page 58: ...he screws with a tiny gap Lock the screws using Loctite 243 Fix the top frame to the top disk Mount all cables for MCU switches screen keyboard and mouse nicely from the beam and up Internal cabling Mount the plastic cover and fix it to the top frame Place the pc screen onto the work station and fix it with the fixture as shown ...

Page 59: ...i XL Service Guide 59 Assemble the cables in a nice way beneath the top frame ...

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