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Esko Kongsberg XL, User Manual

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Esko Kongsberg XL User Manual Download Page 88

12

Kongsberg XL

5.

Follow procedures strictly: 

Chuck Change

and Cleaning 

 on page 95.

Long term storage

More than 4 weeks storage of a spindle or a

MultiCUT

/

MultiCUT-HP

 requires:

1.

Turn the spindle by hand about 20 turn

every 4 weeks.

2.

Spindle must be stored horizontally.

Consider having a replacement spindle

If 

MultiCUT-HP

 is used in regular production,

it is recommended to have a 

Replacement

Spindle

.

The service interval will depend on the type of

operation, and is difficult to predict.
Indication of worn bearings may be increasing

noise, increasing vibrations or decreasing

surface finish.

Note: 

 When replacing a 

Spindle

, torque the

motor clamp to 5 Nm, 44 lbf-in using a 

Torque

Wrench

.

This is a low torque for that screw size.

Also check by hand that the 

Spindle

 rotates

smooth without any resistance.

88

Summary of Contents for Kongsberg XL

Page 1: ...Kongsberg XL User Manual 09 2020 XL ...

Page 2: ...ts to be met by operators 13 5 4 Definition of use 13 5 5 Warning sign explanation 14 5 6 Attention Areas 17 5 6 1 Danger Zones 17 5 6 2 Moving Parts Laser Radiation and High Voltage 17 5 6 3 Loose Clothing 17 5 6 4 Noise Level 17 5 6 5 Ejection of parts when milling 18 5 6 6 Milling stop time 18 5 6 7 i Camera strobing light 18 5 7 Safety devices 19 5 7 1 Overview 19 5 7 2 Emergency Stop Button 1...

Page 3: ...e Grain Direction 35 8 8 Vacuum Zone Selection 35 8 9 Job Execution 36 8 10 Milling Production 36 8 11 Make a Pen Plot 37 8 12 Work with X Pad 37 9 How To Procedures Advanced 41 9 1 Cutting Thick Materials 41 9 2 Hard Board Production 41 9 3 Multi Pass Milling 42 9 4 Job including Reverse Operation 42 9 4 1 Reverse Operation by Left and Right Rulers 43 9 4 2 Reverse Operation by use of Camera 44 9...

Page 4: ... 9 Maintain Tool List More 61 12 Tooling System 63 12 1 Tool handling and care 63 12 2 Tool Inserts with built in motor 63 12 3 Tool Heads available overview 64 12 4 Tool Head mount dismount 65 12 5 FlexiHead 65 12 6 PowerHead 66 12 6 1 ø150 mm Crease Wheel 67 12 6 2 Crease Adapter ø26 mm 68 12 6 3 Perforation Wheel ø60 mm 69 12 6 4 HD Knife Tool 70 12 6 5 V notch Knife 71 12 6 6 Bevel Knife 45 77...

Page 5: ...nd X Pad 111 12 13 3 Limitations 111 13 Tool inserts 112 13 1 Ball Point Pen 112 13 2 Bevel Knife 113 13 3 Bevel Knife U20 114 13 4 Braille Tool 114 13 5 CorruSpeed Knife 119 13 5 1 Tool adjustment 121 13 6 Crease Tool 122 13 6 1 Tool adjustment 122 13 7 Crease Tool 60 mm 123 13 7 1 Tool adjustment 123 13 8 Drill tools 124 13 8 1 Flexi Drill Tool 124 13 8 2 Reboard Drill Tool 125 13 8 3 Drill Bit ...

Page 6: ...justment 147 14 Maintenance 150 14 1 Daily maintenance 150 14 2 Weekly maintenance 150 14 3 Maintenance external equipment 150 15 Fuse Replacement 151 15 1 MPU fuses 151 15 2 X1 fuses 152 15 3 X2 fuses 152 15 4 Y Z fuses 153 15 5 Tool Rotation Reciprocating knife fuses 154 15 6 Sound Insulating Box Circuit Breaker for fan 155 16 Vacuum Cleaner 156 16 1 Vacuum Cleaner Zefiro 156 16 1 1 How to use 1...

Page 7: ...berg AS does not warrant guarantee or make any representations regarding the use or the results of the use of the system or the information contained herein Esko Graphics Kongsberg AS shall not be liable for any direct indirect consequential 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...

Page 8: ...2 Kongsberg XL 2 Change Record Date dd mm yy By Description 30 05 2017 jhbe For XL this is the first edition 30 05 2017 jhbe Work space limitation when using V notch or Bevel knife information added 8 ...

Page 9: ...nual for i cut Production Console This manual is aimed for operators of Kongsberg Cutting Tables and people preparing files for such equipment Another source for information is the manual Get the best out of iPC 2 0 Note Some of the functions and equipments described in this manual are optional 3 2 FCC conformity statement This machine complies with CFR 47 part 15 of the FCC Rules Operation is sub...

Page 10: ... a Job A typical workflow is described with detailed information about each step How to Procedures Advanced Optional functions for the advanced user Cutting Thick Materials advices Hard Board Production advices Multi Pass Milling how to Tool Configuration and Adjustment General information about the tooling and adjustment of tools Tooling System Tool descriptions Maintenance This chapter describes...

Page 11: ...k to topic Menu Bar Edit Options Menu selection From Menu Bar select Edit and then Options This symbol indicates that the function depends upon actual hardware If hardware is not available this functions is hidden This symbol indicates that the function is license dependant 4 3 Pictures and Illustrations Orientation Pictures and illustrations related to the Cutting Table are viewed as illustated h...

Page 12: ...e Manufacturer The Manufacturer is responsible for delivering the system according to Safety Regulation standards 5 2 2 The owner The owner is responsible for Ensuring that the system is used for its intended use only Ensuring that only authorized and trained personnel operate the system Preventive maintenance as described in the maintenance section of the user manual That the local Regulations re...

Page 13: ...his manual Intended use is described in the following chapters Basic Operations Prepare for a Job How to Procedures Advanced Any other use is considered Non intended use Examples of Non intended use Operation by operators not meeting the requirements as described above Unauthorized modifications bridging safety devices removing covers etc Deliberately avoiding the DynaGuard safety system by reachi...

Page 14: ...nection has been removed from the socket outlet for the vacuum pump Note Different instruction for Cxx and Xxx Vacuum cleaner The vacuum cleaner is not disconnected by the mains connection of the cutting table Do not remove the cover of this unit until the mains connection has been removed from the socket outlet for the vacuum cleaner Note Different instruction for Cxx and Xxx IBAG inverter The IB...

Page 15: ...er LASER RADIATION DO NOT STARE INTO BEAM DIODE LASER MAX OUTPUT 1 mW WAVELENGTH 650 660 nm EN 60825 1 1991 A11 1996 CLASS II LASER PRODUCT AVOID EXPOSURE Laser radiation emitted from this aperture General warning Milling tools Milling tools require skill and must be run by QUALIFIED OPERATORS ONLY This is based on Safety issues Protection of the equipment Taking care of expensive materials Knife ...

Page 16: ...are Between Y carriage and rack Between the table top and the moving traverse Underneath the tool head Hearing Protection The Hearing Protection symbol indicates areas where the use of hearing protection is compulsory Eye Protection The Eye Protection symbol indicates areas where the use of eye protection is compulsory Do not leave the machine running if the vacuum cleaner can be over filled This ...

Page 17: ...ger Zone is identified by the means of a yellow black floor marking 5 6 2 Moving Parts Laser Radiation and High Voltage 5 6 3 Loose Clothing While working with this machine do not Use ties Use loose necklaces Use scarfs 5 6 4 Noise Level Hearing Protection should be used by any personnel exposed to the noise from the machine 17 ...

Page 18: ...ion that the milling bit has come to a complete standstill before touching it Note Only specially trained operators are allowed to operate milling tools 5 6 7 i Camera strobing light If your system includes i Camera please read this warning carefully WARNING i Camera is equipped with LED strobing light The LED default frequency 10 Hz is in a range that can cause photosensitive epileptic reactions ...

Page 19: ...ch positions OUT Emergency Stop is switched OFF IN Emergency Stop is switched ON Servo Power to the machine is switched off On machines before approx 2020 Mains Power to the machine is switched off Note Activating the Emergency Stop Button does not provide a guarantee against injury Due to the high kinetic energy of moving parts do not underestimate Stop Distance of traverse Y carriage and Tool He...

Page 20: ...ism mounted on each end of the traverse Machine movement will stop and Servo Power will be switched off if One of the light beams are broken The stop mechanism is activated for instance when a person is standing too near the table Continue after DynaGuard is triggered To continue operation proceed as follows 1 Ensure the table is free from obstructions and ready for operation 2 Reset the Safety Sy...

Page 21: ...maximum level of 98 5 dBA 5 9 Procedures in case of malfunctions Trouble shooting and repair shall be executed by Authorized Personnel only Contact a Esko Service Organization 5 10 Check before operation Before operating the equipment check the following Electrical cables without damage Clean workspace Unobstructed motions Servo lamp functioning Milling spindle warning lamp functioning Electrical ...

Page 22: ...t supposed to be in the machine area Do not work or stay beneath the traverse while the machine is working Y carriage 2 The top of the Y carriage is un protected in all four directions Actions Do not bend down over the table or traverse while the machine is working Inside cable chain 3 There is a risk for squeezing between the cable chain and the table base frame Actions Stay out of this area whil...

Page 23: ...out of this area while the machine is working Gallows on machines with MultiCUT 5 The gallows is un protected Actions Stay out of this area while the machine is working Under the lower DynaGuard beam 6 It is possible to reach under the lower DynaGuard beam into tool hazard areas Intentionally doing this is very dangerous and considered as non intended use Touching the milling bit while rotating 23...

Page 24: ...o 4 seconds This is sufficient time to access and touch the milling bit before it has come to a stop It is crucial that the operator is trained to always ensure by visual inspection that the milling bit has come to a complete standstill before touching it 24 ...

Page 25: ... X1 end of traverse Y Y axis X2 X2 end of traverse Z Z axis The arrows indicates positive moving direction 6 2 Main Power Switch Switch positions O the Main Power to the machine is switched OFF I the Main Power to the machine is switched ON 6 3 Operators Panel Power On 25 ...

Page 26: ...anel Reference Point Press this button to set Panel Reference Point If Fixed Reference Point is disabled the current position of Laser Pointer is set as the new Reference Point Move to Table Zero Press this button then the Start button to move the tool head to Selected Reference Point The Table Zero Mode is automatically selected at Power on The system remains in the Table Zero Mode until Table Ze...

Page 27: ...incremental movement can be changed from Machine Configuration Setup Tool Down Press the Tool Down button to manually operate the machine with a tool in the down position Cancel by pressing Tool Down a second time Vacuum release mode For details about this function see separate chapter Vacuum control If activated for more than 2 seconds this button activates the Manual Belt Clamp function 6 4 Vari...

Page 28: ...ir Tube to Tools and Valves For details regarding air supply requirements see Site Preparation Manual The Air Pressure should be adjusted to minimum 6 bar 6 kg cm2 6 105 Pa Recommended pressure level is 7 bar 7 kg cm2 7 105 Pa Where to find Air Pressure Regulator 6 6 Application programs available After installation of iPC the following application programs are available iPC Control program for th...

Page 29: ...power up the system and get ready to work 1 Front End PC Switch on the PC and the monitor 2 Table Power Switch the table on using the Main Power Switch Note After power off wait minimum 5 sec before the system is switched on again 3 iPC From Desktop double click the icon for iPC Check that no error message indicates faulty conditions 4 Safety System Reset the Safety System by pressing the Pause pu...

Page 30: ...es Any malfunction of the lamp must be corrected as soon as possible since the lamp is a safety feature 8 The table is now ready for operation 7 2 Reset Safety System Press Pause to Reset Safety System 7 3 Power Off Sequence Follow these steps to power down the system 1 Servo Power Press the Servo On pushbutton to switch Servo Off 2 Table Power Turn Table Power off using the Main Power Switch Note...

Page 31: ...amp starts flashing To continue operation proceed as follows 1 Ensure the table is free from obstructions and ready for operation 2 Reset the Safety System by pressing the Pause pushbutton 3 The Warning Lamp on top of the Y carriage should be constantly lit not flashing Observe that Servo Power is switched on 4 Press Start to continue 31 ...

Page 32: ...The Starting Point in this procedure is to Create a Job from a file already available in My Jobs List Detailed information about the complete iPC workflow is available in the following manuals User Manual for i cut Production Console Get the best out of iPC 2 0 Here a step by step procedure is provided that can be used as a check list 8 2 Main Reference Point in iPC In XL Guide the Main Reference ...

Page 33: ... point 2 in the figure above Using this Main Reference Point all tools and cameras will be available inside the Limited Work Area If you want to run jobs using Main Zero point 1 as your Reference Point you should Establish a User Defined Reference Point in position X 20 Y 80 mm from Main Reference Point Use this User Defined Reference Point as the Reference Point for your jobs To simplify prepare ...

Page 34: ...les as before using the Main Reference Point as your Reference Point 8 3 Create Job In My Jobs List double click a file My Job Actions Create Job A new Job is created based upon currently selected file in My Jobs List 8 4 Layer Setup Opened Job Layers Ensure proper Layer Setup 8 5 Production Setup Opened Job Production Setup 34 ...

Page 35: ...f this is a High Accuracy or a High Speed Job 8 7 Flute Grain Direction Properties Bar Flute Grain Direction Verify that the Flute Grain Direction corresponds to the material 8 8 Vacuum Zone Selection Machine Panel Toolbar Vacuum Zones From the Vacuum Zone setup dialog configure a suitable vacuum area for the job Select Vacuum Zones that corresponds to the outline of your material Proper selection...

Page 36: ...set Safety System 4 Complete a Table Top Reference sequence to update Tool Height measurement 5 Position the material on the Cutting Table 6 Press Vacuum On to start the Vacuum Pump If you are running with Automatic Vacuum Control enabled the pump will start automatically when Start is pressed 7 Press Start to execute the Job 8 10 Milling Production Before execution check vacuum cleaner 36 ...

Page 37: ...execute a job Ensure the Ballpoint Pen is clean and ready to use 8 12 Work with X Pad Measuring modes Machine Connection Machine Configuration Setup Two modes are available Manual Tool height is manually adjusted using the tool height adjustment wizards available from the Tool Configuration dialog Automatic The tool height is automatically measured using X Pad as described in next chapter Automati...

Page 38: ...ring sequence is started 3 Place the measuring pad with the Laser spot in center or jog the machine until the Laser spot is in the middle of the measuring pad Press Start to initiate measuring Indication that the measuring sequence is active A measuring sequence is indicated by Continuous light in the Tool Override Down button Continuous light in the Laser Pointer Start button light is flashing Pa...

Page 39: ... value means down into the material Current offset setting The initial offset value when the dialog was opened is displayed How to start a measuring sequence in the middle of a job Two methods are available 1 Measure after Stop at Tool Select Stop before use The execution will stop for each tool change and a tool height measuring sequence can be carried out 2 You press Pause In both cases the tool...

Page 40: ...8 Kongsberg XL All Measuring Pad operations are cancelled by Press Close in the active dialog Press Pause on Operators Panel 40 ...

Page 41: ...ife Tools only Cutting Depth when Depth Referenced from Top is disabled Note This function is useful for all materials with an un even surface 9 2 Hard Board Production To prepare hard board materials the procedure is as follows 1 Mill through the top layer using MultiCUT 2 Cut through the mid section using the HF VibraCut Knife 3 Mill through the bottom layer using MultiCUT 1 Ensure that the mill...

Page 42: ... Reverse Operation is used if operations need to be done from both sides There are two types of Reverse Operations Ruler based Camera based Which methode is available is HW dependant and described in the following sections If Crease needs to be done from both sides ruler based Reverse Operations is commonly used For Print registration Regmarks need to be read before sheet is flipped and processed ...

Page 43: ...d tool does not currently allow reverse side operation Can be configured in Configure Tools dialog Status 2 Selected tool allows reverse side operation Turned off Status 3 Selected tool allows reverse side operation Turned on Turn means that the material is flipped over side to side Tumble means that the material is flipped over top to bottom 9 4 1 Reverse Operation by Left and Right Rulers 43 ...

Page 44: ... you want to add a Crease line on the front side of a material that you normally prepare from the rear side This function requires that the table has Left and Right Rulers physically mounted and selected in HW configuration and that the job is without Regmarks 9 4 2 Reverse Operation by use of Camera Workflow Step 1 Regmarks and corners are read by the Camera Step 2 the sheet is flipped turned or ...

Page 45: ...ion with Step and Repeat Reverse Operations in combination with Step and Repeat and Left and Right Ruler For each copy defined by Step and Repeat you have to move the sheet first against the Right Ruler then against the Left Ruler Reverse Operations in combination with Step and Repeat and Camera For each copy defined by Step and Repeat you have to flip the sheet and read Regmarks and corners 9 5 W...

Page 46: ...9 Kongsberg XL For more information go here 46 ...

Page 47: ...ettings One time adjustments completed at the factory The functions are included here as a reference They are not used during normal operation If necessary they should be repeated as indicated in the function description 1 Adjust X1 to X2 Angle 2 Register Table Size 4 Set Ruler Position 5 Set Main Reference Point 6 Map Table Top Surface 8 Vacuum Setup 9 Router Setup Adjustments to customize the ta...

Page 48: ...o X2 Angle function 2 Follow the instructions exactly as given by the wizard Note Select a set of drilled vacuum holes 1 and 2 in the table top as reference 10 3 Register Table Size Machine Connection Machine Configuration Installation_ Register Table Size This wizard moves the Tool Head from edge to edge of the Cutting Table in order to measure the table size Typical use is after maintenance or r...

Page 49: ...d out 10 5 Set Main Reference Point Machine Connection Machine Configuration Installation_ Set Main Reference Position Follow instructions from the wizard Use this wizard to establish the Main Reference Point R Typical use is after maintenance or repair if the Main Reference Point has been accidentially moved The Main Reference Point is a fixed position on the Cutting Table marked as a cross of dr...

Page 50: ...ts break the 5 mm limit iPC now always compensate based on table top mapping A registry setting is available to enable the old behavior 10 7 Reference Points and Coordinate System Reference Points settings is maintained from Menu Bar Edit Options Reference Points All X and Y coordinates in the Input File have the selected Reference Point as origin Two modes of operation are available Using Main Re...

Page 51: ... Points The Ruler System ensures an easy and correct positioning of the material on the table The Main Reference Point shall be defined dr 10 mm 0 39 in inside the ruler When you use the Right Ruler the Reference Point will automatically be moved to an identical distance from the Right Ruler as it is defined from the Left Ruler The Right Ruler is normally used for Reverse Score operations At the s...

Page 52: ...educed to a value of the maximum jog speed Machine Connection Machine Configuration Setup_ Jog Speed Specify low and high Jog Speed Incremental Jog Step Size The size of the Incremental Jog movements can be customized Machine Connection Machine Configuration Setup_ Incremental Jog Specify Step Size to be used Jog Directions Machine Connection Machine Configuration Setup_ Jog Panel Direction Use th...

Page 53: ...ocedure 1 Remove all materials from the table surface 2 Measure on top of the cutting underlay or conveyor belt 3 If the table is equipped with a conveyor belt avoid measuring directly on the belt junction 4 Execute the Table Top Reference function 5 In the wizard press OK to start measurement 10 12 Milling Unit Setup Machine Connection Machine Configuration HW Configuration Milling Unit setup Fro...

Page 54: ...10 Kongsberg XL 10 13 Board Size Not implemented yet 54 ...

Page 55: ...nection Tool Configuration The Tool Configuration dialog is used for all tool settings and adjustments 11 2 Adjust Active Tool From the Adjust Selected Tool dialog all Tool Adjustment Wizards are executed The following procedures are general descriptions of how to adjust the tools 55 ...

Page 56: ...le Top Reference 11 3 Tool Height Calibration 1 Select the Tool to be adjusted 2 Press the Adjust Active Tool button to enter the wizard selection dialog 3 Select Tool Height Calibration 4 Follow the instructions given by the wizard step by step 5 Repeat the procedure for all tools 11 4 Lag Settings for Rotating Tools 1 In the Configure Tool dialog select the tool to be adjusted 2 Press the Adjust...

Page 57: ...ck of the Knife Blade Enter the value as measured or as found using the Lag test see below Width knife bottom width Enter the measured knife bottom width Lag Test Run this wizard to obtain correct Knife Lag value Follow the instructions in the dialog Add the measured value to the displayed value 57 ...

Page 58: ...ust Active Tool button to enter the wizard selection dialog 3 Select Rotation adjustment 4 Follow the instructions given by the wizard step by step 5 Repeat the procedure for all Tools mounted Manual Adjustment 1 Place an appropriate test material on the table and switch Vacuum On 2 From Tool Configuration dialog select one Tool 3 Press Adjust Active Tool to enter the Wizard Selection Dialog 4 Sel...

Page 59: ...propriate test material that means a thin paper on the table any significant material thickness will create a misleading offset in this wizard 2 Switch vacuum on 3 Select the Tool to be adjusted 4 Press the Adjust Active tool button to enter the wizard selection dialog 5 Select Center Offset Adjustment 6 Follow the instructions given by the wizard step by step 7 Repeat the procedure for all Tools ...

Page 60: ... Center Offset and angle Sometimes it might be necessary to fine tune the adjustments obtained using the wizards Use this dialog to modify the adjustment values for angle and center offset 1 Select the tool to be adjusted 2 Press the Manual adjustment of button to enter the adjustment dialog 3 Key in or use the up down arrows to specify the wanted offset 4 Press Activate to enter the value 5 Test ...

Page 61: ...step 11 9 Maintain Tool List More The More dialog contains selections to Ignore Delete or Add to the Tool List The Tool List contains Tools that you can select for the available Tool Positions Ignore Automatic Tool Identification Ignore Automatic Tool Identification may be used when the Automatic Tool Detection fails and manual tool selection is necessary If Ignore Automatic Tool Identification is...

Page 62: ...11 Kongsberg XL Add new Tools Add tools that fails during Automatic Tool Detection The Tool is added to the Tool List 62 ...

Page 63: ...nserted or removed from their stations No excessive force should be applied Tools should not come in contact with hard surfaces while removed from their stations either temporarily or for storage The Tools and their stations should be kept clean with a soft brush 12 2 Tool Inserts with built in motor Some of the tool inserts has a built in motor such as the reciprocating knife tools RotaCut and th...

Page 64: ...e plug 12 3 Tool Heads available overview FlexiHead FlexiHead is a Multi purpose Tool Head prepared for the following tools Bevel Knife KissCut Knife Psaligraphy Knife Crease Tool Knife Tool Reciprocating Knife CorruSpeed Knife Tool MicroCut RotaCut Knife Drill Tool Pen Foam Knife 64 ...

Page 65: ...2 5 FlexiHead Tool Head Description 1 Tool positions 1 2 3 with locking knobs 2 Outlet for Reciprocating Knife motor 3 Laser pointer 4 Measuring foot material hold down foot Has 3 functions a Measure the thickness of the material on the table b Mapping Table Top Surface c Keep material down during knife operations 65 ...

Page 66: ...t Correct tool height relative to table top Lag Setting Tool Rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset to Laser Pointer 12 6 PowerHead Tool Head Description 1 Tool position 1 FlexiHead tool insert 2 Tool position 2 FlexiHead tool insert 66 ...

Page 67: ...t wizards see Tool Configuration Working area The working area is reduced with 62 mm 2 4 in Y for tool position 1 Note When running with V notch knife in tool position 3 the working area is slightly reduced due to the slanted angle used when tool down Back score and PowerHead To be able to run a job including back score you have to establish a fixed reference point at a position reachable for all ...

Page 68: ...high recycle content without breaking the liner A broad range of wheels with different shapes is available How to mount dismount the Crease Wheel Insert remove the latch pin Insert remove the Cotter Pin 12 6 2 Crease Adapter ø26 mm The Crease Adapter allows 26 mm 1 in crease wheels to be used in the Heavy Duty crease tool position The tool is adjusted and operates as an ordinary crease tool 68 ...

Page 69: ... 3 Perforation Wheel ø60 mm Use Perforation Wheel to prepare perforation lines at high speed Suitable for corrugated board up to C flute 4 mm 0 16 in Perforation Wheel assembly Parts in assembly Ensure the path is clean 69 ...

Page 70: ...matically possible to add an Offset Value Lag Setting The Lag value depends upon the Blade Adapter Nominal value is 0 mm Tool Rotation Adjust Tool Angle tangential to Moving Direction Center Offset Adjust Tool sideways until centered Tool Offset Adjust offset relative to Laser Pointer For more information about how to run the Adjustment Wizards see the Tool Configuration chapter 12 6 4 HD Knife To...

Page 71: ... crease tool position The tool is adjusted and operates as an ordinary knife tool Knife Blade correctly positioned inside the adapter The HD Knife Tool is ready with the Knife Blade mounted 12 6 5 V notch Knife V notch Knife mounted on a Heavy Duty Unit 71 ...

Page 72: ...move the blade 1 3 Insert a new Knife Blade and make sure that it is aligned with the alignment pins in the tool head 4 Mount the new tool 5 Select Option Tool Configuration Adjust Active Tool Tool Height Calibration wizard to assure correct height of the new knife Tool adjustment For the V notch Knife we recommend the manual procedures for tool rotation and centre offset adjustment When adjusting...

Page 73: ...sideways until centered Tool Offset Adjust offset to laser pointer For more information about how to run the adjustment wizards see Tool Configuration V notch Knife settings are maintained from Opened Job Layers Edit Layer Menu Bar Layer Edit Layer How to set the depth of the V notch Knife 1 The default depth of the V notch Knife is cut through the entire material 2 Define the depth of the V notch...

Page 74: ... indicates the cut direction Different angles A wide range of V notch knives is available providing different knife angles v 15 o 22 5 o 30 o 45 o 47 5 o Note On XL this tool will reduce the work area by approximate 25 mm 1 in in some axes V notch knife tools modes of operation Opened Job Layers Tab Edit Layer Menu Bar Layer Edit Layer 74 ...

Page 75: ...gles V notch specific parameters Rotational compensation Rotational compensation is used to optimize V notch Bevel Cut quality in challenging materials and use cases This feature will pre load the knife blade and overcome mechanical flexibility in the system Notch angle Notch Angle is used for the VariAngle unit only and determines the angle of the blade into the material 0 o is a vertical cut For...

Page 76: ...across flute when Crease is selected Waste Cut Waste Cut adds a third cut line to ease removal of waste Geometry When the knife angle is 45 o and you cut through the material the width of the cut is W 2 x h Folding If you prepare a material for folding the following rules applies Adjust the cutting depth to just above the bottom liner 76 ...

Page 77: ...tics This illustration shows how the parameter dW is used to ensure a nice folding result Waste Cut function adjustment This illustration shows a typical use of Triple Cut Function The middle wall is not cut by 2 or 3 making the material impossible to fold The Triple Cut Function 1 cut the middle wall and you can fold the material nicely Adjustment sign and cut direction 12 6 6 Bevel Knife 45 Beve...

Page 78: ...op Lag Setting Default lag value for the long foam knife is 4 5mm 0 18 Tool Rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset to Laser Pointer For more information about how to run the adjustment wizards see Tool Configuration Partial through cut Partial through cut is specified as an absolute value or a percentage...

Page 79: ...Blade A set of knife protection handles are available Use them for safe knife handling Use them for safe knife storing Loosen the fixing screw replace the Knife Blade and fix it again When not in use protect the Knife Blade using the handle Disable Material Thickness Measurement Opened Job Production Setup Material Handling For the Foam Knife Tool the Disable Material Thickness Measurement functio...

Page 80: ...lay During Tool Up movements the knife is lifted to its top position 12 8 MultiCUT 12 8 1 Introduction MultiCut MultiCUT is a special purpose tool head which can be equipped as follows Two general tool positions prepared for the standard FlexiHead tools Milling tool equipped with a high speed milling spindle Spindle motor Ibag HF 45 Power rating max 1 kW Cooling system Air Shank size max 6 mm RPM ...

Page 81: ...ange Replacing a chuck Replacing a chuck is described in the User Manual for the machine This chapter is included just to remind you how important it is to use the Chuck Changing Tool available and a shaft to ensure correct mounting From left Chuck changing tool shaft with diameter as the chuck and chuck Chuck change assembly Ready to be inserted into the spindle 81 ...

Page 82: ...1 Suction house with brush for chip removal During normal operation the house is in down position When changing bit the house should be locked in its upper position 2 Air blow adjustment Air blow is used for router bit cooling and to ease chip removal Adjust for proper operation There is also an air blow inside the spindle but no user adjustment is necessary 3 Warning lamp for spindle running 4 Ch...

Page 83: ...th one 6 mm chuck on delivery 3 Spindle When MultiCUT is not in use the suction tube is fixed to the traverse as shown here 12 8 3 Safety issues Unattended Operation Depending upon the material processed milling introduces some risks It is a good rule to keep an eye on a milling job being executed Pay special attention to Do not leave the machine running if the vacuum cleaner can be over filled Th...

Page 84: ...ng hit by small work pieces or by a broken milling bit Warning Regularly inspect and clean the suction house to prevent it from clogging Failing to do so could in worst case result in a fire when a hot milling bit is in contact with the debris Ejection of parts There is a potential risk that personnel can be hit by breaking milling bits or small pieces of processed material Therefore eye protectio...

Page 85: ... inspection that the milling bit has come to a complete standstill before touching it Handling of milling tools Before dismounting the milling tool from the machine always replace the milling bit with a dummy bit A chuck shall never be closed empty and leaving the milling bit in gives high risk for injury during tool handling High temperatures Clean surface Keep the table and material surfaces cle...

Page 86: ...rp milling bit 2 Use correct RPM for the actual bit and material 3 Reduce the X Y speed If the motor is running above a critical limit the execution will stop and a message is displayed Use of non balanced bits One flute bits are by nature Non Balanced and may destroy the Spindle if used wrong Therefore one flute bits with cutting diameters above 4 mm 5 32 inch must be run with a maximum RPM of 40...

Page 87: ...indle with Pressurized Air disconnected This will destroy the Spindle Use Clean Air The Spindle is sensitive for the Pressurized Air quality Regularly check the Air Pressure Reduction Valve according to the Maintenance on page 150 section Maintain bit clamping Un proper bit clamping may cause the bit to slip in the chuck and damage the Table Top 1 Keep the bit shaft clean 2 Avoid greasy fingers 3 ...

Page 88: ...pindle If MultiCUT HP is used in regular production it is recommended to have a Replacement Spindle The service interval will depend on the type of operation and is difficult to predict Indication of worn bearings may be increasing noise increasing vibrations or decreasing surface finish Note When replacing a Spindle torque the motor clamp to 5 Nm 44 lbf in using a Torque Wrench This is a low torq...

Page 89: ... the Vacuum Cleaner can be over filled This might cause damage 2 Be aware the risk of suction house and suction tube clogging 12 8 5 Milling advice Follow this advice for obtaining the best possible milling results Milling bits For thin materials use bits with short cutting length 89 ...

Page 90: ...be taken when using bits with cutting diameter larger than shank diameter Bits with small cutting diameter 3 4 mm 0 12 0 16 in are more balanced than bits with larger cutting diameter Thus they can run with higher RPM normally 60 000 Use large diameter bits 5 6 mm 0 20 0 24 in when needed only Typical use is to get rid of the chips in thick materials Max RPM MultiCUT HP 60 000 90 ...

Page 91: ...Feed rates One flute Bits do have a good chip flow and allow for large feed rates 0 1 0 2 mm tooth 0 004 0 008 in tooth can be a starting point for optimization in most materials This gives a feed rate of of 4 8 m min 2 6 5 2 ips at 40 000 RPM and 6 12 m min 3 9 7 9 ips at 60 000 RPM Light materials like PVC foam can be run much faster The surface finish or the Power Consumption will normally dete...

Page 92: ...the situation 1 Use Milling Bits with smaller Milling diameter 2 Cover unused table area to increase Vacuum Hold Down Level 3 Use Wash Out functions instead of creating small waste parts Using other tools in combination with the MultiCUT HP It might be necessary to reduce the acceleration in order to achieve an optimal Cutting Quality when combining a heavy tool head with high quality cutting tool...

Page 93: ...k Open Close lever down to open the Chuck Put the bit in a proper storage container Insert a new milling bit Close the Chuck 3 Only the round part of the shaft should be inside the Chuck See the Bit Length and Position on page 99 chapter for more information 4 Release the Lock to allow the Suction House moving down to its down position 93 ...

Page 94: ...nt depths Use the Sleeve Adjustment Tool in order to Ensure correct insertion of milling bit Ensure equal bit height when replacing a milling bit Additional tool height adjustment not necessary Safe operation the sharp part of the milling bit is protected Use the 20 mm 0 8 in Sleeve Adjustment Tool for milling materials up to 16 mm 0 6 in Use the 28 mm 1 1 in Sleeve Adjustment Tool for milling mat...

Page 95: ...leaning on page 95 section about how to unscrew the chuck 12 8 7 Chuck Change and Cleaning Clean the taper and the chuck regularly for proper operation and optimum life time at least once a week but more often if necessary Follow the procedure strictly Normally the chuck has a long lifetime Extended vibrations or impacts may hurt the chuck and cause bad milling results Trying a new chuck is the ea...

Page 96: ...y Compressed Air for cleaning 2 Apply the 17 mm key to hold the Spindle Rotor Note Do not turn the rotor when Chuck is in open position This might damage the Spindle 3 Enter the Chuck Tool with a Dummy Bit into the chuck 4 Hold the rotor with the 17 mm key and unscrew the chuck using the Chuck Tool 96 ...

Page 97: ...ust be pressurized 5 Use the Taper Brush to clean the Taper 6 Push the Air Clean Button to help remove contamination 7 The Taper Brush must be absolutely free from grease or oil If necessary you must clean it with alcohol before you use it This is very important as it has direct consequence for the clamping force 97 ...

Page 98: ...reen arrows Avoid the clamping area red arrow Do not use oil as it could enter the clamping area and reduce the clamping force 9 Torque up the chuck by hand using the Chuck Tool with a Dummy Bit Hold the rotor with the 17 mm key 10 Close the chuck on a Dummy Bit 11 Chuck Maintenance Kits are available in the Esko Store on www esko com 98 ...

Page 99: ... 12 8 9 Bit Length and Position Keep distance d small For best performance and minimum wear do not let the bit stick out more than necessary Use bits with short cutting lengths for thin materials For proper clamping keep distance e 20 mm 0 8 inch as a minimum If distance d is more than 28 mm 1 1 inch be aware that the bit then extends below the underside of the traverse If the machine has extended...

Page 100: ...ve to reduce the suction force 12 8 11 Tool Adjustment For FlexiHead tool positions complete relevant adjustments as described for FlexiHead For the milling unit position complete the following adjustments Tool Height Correct tool height relative to table top The tool tip should touch the material surface Tool Offset Adjust offset to Laser Pointer For more information about how to run the adjustme...

Page 101: ...op of the actual material or on top of any other test material Note This adjustment can be completed both on surface U and M not on C but we recommend the described solution The following rules apply when milling Mill on cutting underlay C To avoid damage to the cutting underlay the downward movement of the milling bit is stopped 2 mm 0 08 inch above the cutting underlay Thus it is not possible to...

Page 102: ...on house Clean the suction house when necessary with acetone and a q tip A smooth surface will ease the chip removal Vacuum clean the milling underlay The Vacuum Cleaner can be used for automatic cleaning of the felt mat Prepare program to make a file that covers the actual area Set bit size to 65 mm 2 5 inch Hint Make a file name that reflect the size used Prepare Layer Setup with low spindle spe...

Page 103: ...CUT HP 12 9 1 Introduction This is chiller 1 replaced in October 2016 by a new model named chiller2016 Flow Measurement During operation check the water flow level displayed on the chiller meter For proper operation the flow level should be 1 0 l min 103 ...

Page 104: ... failure cable defective connection failure sensor defective IA Water level of water flow too low HI Temperature of cooling medium too high LO Temperature of cooling medium too low During normal operation the cooling medium temperature is displayed More information is available from the Operating instructions for the chiller 12 9 3 Chiller Heater Operation Notes 1 The Chiller Heater is optional 2 ...

Page 105: ...ents are operating Red light on fault condition over heating cable breakdown Program selection Press and hold the Menu button for 3 sec Use arrow keys to select program Press Menu button to confirm selection Temperature setting Use arrow keys to select temperature Press Menu button to confirm selection Programs available Program Temperature range from o C Temperature range to o C Hysteresis 0 Fros...

Page 106: ...e years Chiller 2020 differs from previous models by being a heat exchanger which will not be able to lower the temperature below ambient Specifications Dimensions W x D x H 480 x 580 x 430 mm 19 x 23 x 17 in Chiller 2016 W x D x H 610 x 480 x 450 mm 24 x 19 x 18 in Chiller 2020 Weight Empty 40 kg 88 lbs Chiller 2016 Empty 24 kg 53 lbs Chiller 2020 Filled with liquid 49 kg 108 lbs Chiller 2016 Fil...

Page 107: ...o C 66 o F The chiller is equipped with an internal automatic heater First time startup Check that the supply matches the rated voltage Check that the electrical connection has been made correctly 12 10 3 Error Conditions One common error signal is routed from the Chiller system to the inverter and further into the control system The following error conditions are monitored Temperature out of rang...

Page 108: ...o F L1 Temperature of cooling medium too low 19 o C 66 o F Continue after error situation Find root cause for the error situation and fix it Flow too low is normally caused by a squeezed water hose Switch chiller unit OFF and ON again More information is available from the Operating instructions for the chiller 12 11 Measuring Foot The Measuring Foot has 3 functions 1 Measure the thickness of the ...

Page 109: ...Laser Pointer The Laser Pointer L in the illustration is a Class II laser beam pointing device Wavelength 650 nm 1 mW The Laser Pointer is used in adjustment wizards and job execution to indicate current position on the table The Laser Pointer is lit as long as it indicates the correct current position If there is no manual operation of the table the Laser Pointer will be switched off after a 30 s...

Page 110: ...ed out Ballpoint Pen Tool Braille Tool CorruSpeed Knife Tool Drill Tool MultiCUT MultiCUT HP Psaligraphy Knife Tool RM Knife Tool Procedure The calibration wizard is initiated from Option Table Option Calibrate Measuring Pad The Measuring Pad calibration dialog appears Follow the instructions in the wizard to complete calibration Indication that the calibration sequence is active A calibration seq...

Page 111: ... in two ways 1 The general depth of a tool is entered in Menu Bar Advanced Configure Tools menu 2 The depth for a certain job is entered in Layer Setup 12 13 3 Limitations The following tools can be measured using X Pad Ballpoint Pen HD Crease MP HF Knife V notch Knife Bevel Knife HD Knife Reciprocating Knife Crease Tool MultiCUT RM Knife Drill Tool MultiCUT HP The following tools will not be meas...

Page 112: ...of the tool Ball Point Pen tool is prepared for Space Pen refills Tool assembly and pressure adjustment A Inner sleeve The ball point pen refill is fixed inside the sleeve using a screw Use Allen Key 3 mm B Sleeve holder with spring and pressure adjustment knob Adjust tool pressure using the screw C Lock the adjustment screw using the locking knob D Tool Adjustment For this tool complete the follo...

Page 113: ...in How to replace a Knife Blade Loosen the two screws holding the blade clamp Pull out the old Knife Blade Insert the new blade Ensure the blade align exactly with the alignment pins Fix the blade clamp At left the clamp is removed just to show how to align the Knife Blade After a blade change the tool depth should be checked again How to set the cutting depth of the Bevel Knife The default cuttin...

Page 114: ...cture and thickness For optimal result a fine tuning of the adjustments in the actual material should be carried out For more information about how to run the adjustment wizards see Tool Configuration 13 3 Bevel Knife U20 Bevel Knife U20 is a special purpose tool for 20 degree angled cuts Lag 1 5 mm 0 06 in For proper operation follow instructions for Bevel Knife 13 4 Braille Tool Braille Tool wil...

Page 115: ...ly 5 Push the dispensing mechanism up 6 One sphere should be pushed out from the tool Plunger The tool is equipped with a plunger that serves two purposes 1 To force the spheres into the internal funnel 2 Indicate the number of spheres remaining in the tool If the groove is no longer visible it means that there is a limited number of spheres left in the tool Braille Tool milling bit 115 ...

Page 116: ...aning if the material is 6 mm thick the nominal height setting should be 6 mm minus 6 mm Tool Offset adjustment Machine Connection Tool Configuration 1 Load the Braille Tool with black spheres 2 Cut a piece of double sided tape measuring approximately 20x20 mm 0 8x0 8 in and stick it to the surface of the working area Preferably the milling underlay or your selected substrate It is important that ...

Page 117: ...Configure Tools Braille Tool should be defined with the following parameters enabled Velocity Z max speed Z axis Depth 0 Drill holes on Preparing Layers for Braille Tool Opened Job Layers Edit Layers When making braille signage you need two identical Layers with the braille pattern one for milling holes and one for inserting braille spheres These Layers may consist of circles or points Layer Brail...

Page 118: ...r too high The standard specifies a sphere height of 0 6mm 0 023 Example using 3mm Dibond 1 07mm 3mm 1 93mm Spindle RPM Spindle RPM is material dependent and may require experimentation The values shown in the illustration are suitable for 3mm Dibond Drill holes Drill holes check box should be enabled Layer Braille Tool Z axis Depth Z axis depth should initially be set to the material thickness Th...

Page 119: ...ool Operations in the desktop publishing software To create the Braille patterns select the Braille font and type the text Select a font size which gives correct distance between the dots patterns Details are found in the Raster Braille manual As with other fonts outlines of the text need to be created before creating the output file for i cut Vision Since the Braille patterns should be drilled wi...

Page 120: ...s 1 0 mm 0 04 in less than material thickness One turn CW on A increase d with 1 mm 0 04 in B Foot pressure Adjust foot pressure C scale indicating actual pressure For optimal performance the foot pressure must be adapted to each material Run some test cuts to find the best combination of knife tip exposure and foot pressure Start with foot pressure 5 and test with different knife tip exposures By...

Page 121: ...stment For this tool complete the following adjustments Parameter Description Tool Height The tool tip should touch the material surface Lag Setting The knife lag depends upon the actual knife blade adapter and knife blade Tool Rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to Laser Pointer For more inf...

Page 122: ... wheel into position 13 6 1 Tool adjustment For this tool complete the following adjustments Parameter Description Tool Height The tool tip should touch the material surface Lag Setting The knife lag depends upon the actual knife blade adapter and knife blade Tool Rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered 122 ...

Page 123: ... see Tool Configuration 13 7 Crease Tool 60 mm Use the ø60 mm Crease Tool to avoid cracking the liner Lag is nominal 0 mm The crease wheel is attached to the tool after it has been mounted in the Tool Head Note When working with thin materials avoid crease close to the Ruler 13 7 1 Tool adjustment For this tool complete the following adjustments 123 ...

Page 124: ...o moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to Laser Pointer For more information about how to run the adjustment wizards see Tool Configuration 13 8 Drill tools 13 8 1 Flexi Drill Tool How to replace a drill bit Push the drill bit towards the bottom of the Chuck Use the wrench to fix the bit in the Chuck After a bit change the tool depth...

Page 125: ...or drill bits 0 5 6 mm 0 02 0 24 inches The motor RPM is adjustable from 100 1000 specified in Layer Setup Inside one job only one RPM is available If different RPMs are specified the highest value will be used How to replace a drill bit After a bit change the tool depth should be checked again 13 8 3 Drill Bit dimensions This figure shows the drill bit requirements for the tool to operate properl...

Page 126: ...ill Tool in Sample Making see Service Guide for ArtiosCAD Kongsberg integration available on the documentation DVD 13 9 Foam Knife The Foam Knife tool for FlexiHead is a special purpose tool for cutting foam materials up till 1 25 mm The tool is available for all tables with raised traverse Note As the Foam Knife is longer than the other tools in the Tool Head it is not possible to run the Foam Kn...

Page 127: ...0 1 How to replace a Knife Blade Follow instructions for Static Knife 13 10 Ink Tool Two ink tool models are available Liquid Ink Tool and Fibertip Tool Lag is nominal 0 mm 13 10 1 Liquid Ink Tool Liquid Ink Tool is for ink drawing on foil The tool is prepared for Staedtler 727HPK35 9 insert 127 ...

Page 128: ... tool assembly 13 10 2 Fibertip Tool Fibertip Tool is for ink drawing The tool is prepared for Staedtler Lumocolor insert Fibertip tool assembly 13 10 3 Tool adjustment For this tool complete the following adjustments 128 ...

Page 129: ... information about how to run the adjustment wizards see Tool Configuration 13 11 KissCut KissCut is a special knife tool for vinyl cutting The cutting depth is controlled by the downward knife pressure For applications where a more accurate depth control is required a simple foot solution is available The tool is prepared for a wide range of Knife Blades Lag is nominal 0 mm Description A complete...

Page 130: ...his hand tool when removing and inserting knives into the tool When inserting a new Knife Blade ensure the blade is correctly positioned relative to the Alignment Pin Tool pressure Knife pressure is adjusted by turning the Pressure Adjustment 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 ...

Page 131: ...and knife blade Normally lag 0 Tool Rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to Laser Pointer For more information about how to run the adjustment wizards see Tool Configuration 13 12 MicroCut The MicroCut tool is a special purpose knife tool for applications where exact cutting depth is required ...

Page 132: ... execution C Tool height adjustment How to change Knife Blade 1 Remove the knife tool from the Tool Head 2 Remove the sliding sleeve from the tool 3 The Knife Blade is held by a hex screw A 1 5 mm key will fit 4 Loosen the hex screw and insert the new blade 5 When inserting the new blade please make sure that a The back of the Knife Blade is aligned along the reference edge of the blade socket To ...

Page 133: ...izards see Tool Configuration 13 13 Psaligraphy Knife Note iPC version 2 0 or higher is required to run this tool Psaligraphy Knife is a tool for cutting of fine details in paper and folding carton Lag is nominal 0 mm Replace Knife Blade For Knife Blade change remove the foot The locking screw will always point towards the cutting direction Note Be extremely careful when mounting the foot 133 ...

Page 134: ...ool Rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to Laser Pointer For more information about how to run the adjustment wizards see Tool Configuration 13 14 RBI 90 16 Rigid Board Insert Insert remove Knife Blade Ensure the blade is correctly aligned Use Allen Key 3 mm to fix loosen the Knife Blade Afte...

Page 135: ... in Tool Rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to laser pointer For more information about how to run the adjustment wizards see Tool Configuration 13 15 Reciprocating Knife Reciprocating Knife is available in two models Reciprocating Knife Running with 6000 RPM and amplitude 0 15 mm 0 006 inch...

Page 136: ...ool Common to both models To reduce material tear a foot is available The same set of knife adapters can be used Replace Knife Blade Pull out the electrical connection Note Pull using the connector not just the cable Remove the foot by pulling the foot straight out Loosen the screw A and replace the knife Ensure the knife has correct position relative to the screw Push the knife down while the scr...

Page 137: ...on Tool Height The tool tip should touch the material surface Lag Setting The knife lag depends upon the actual knife blade adapter and knife blade Tool Rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to Laser Pointer For more information about how to run the adjustment wizards see Tool Configuration 13 ...

Page 138: ...a sheet of corrugated material 5 6 mm 0 2 inch when executing the wizards Parameter Description Tool Height The tool tip should touch the material surface Lag Setting The knife lag depends upon the blade adapter Nominal value is 0 4 mm Tool Rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to laser pointer...

Page 139: ...ot suitable for designs containing short lines in combination with sharp angles The RotaCut knife tool is prepared for Decagonal Knife Blades ø25 mm 1 inch Tool adjustment RotaCut is adjusted in the same way as the other insert tools regarding rotation angle and offset but tool height is manually adjusted Tool Height Tool Height for RotaCut is manually adjusted using the tool height adjustment wiz...

Page 140: ... Configuration How to replace the Knife Blade Carefully put the decagonal blade onto the shaft Ensure the blade is properly seated Mount the nut Use the spanner and the hexagonal screw driver to fix the blade properly Observe the alignment pin in the foot and the groove in the tool shaft Position the foot onto the tool shaft as shown at left Note This operation has to be carried out after the tool...

Page 141: ...proper corner cutting Tool Adjustment Use the standard adjustment wizards when adjusting the knife We recommend using a sheet of corrugated material 5 6 mm 0 2 inch when executing the wizards Parameter Description Lag Setting See above Tool Height See above Tool Rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset rel...

Page 142: ...erg XL 13 18 Static Knife Static Knife is a multipurpose tool allowing a wide range of Knife Blades Lag nominal value is 0 3 mm Insert Knife Blade After a blade change the tool depth should be checked again 142 ...

Page 143: ...iption Tool Height The tool tip should touch the material surface Lag Setting The knife lag depends upon the actual knife blade adapter and knife blade Tool Rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to Laser Pointer For more information about how to run the adjustment wizards see Tool Configuration...

Page 144: ...the tool position Position the tool adapter onto the shaft Observe Alignment Pin orientation Keep the knife adapter in this position while you turn the tool shaft in order to lock the tool adapter in its position How to set the cutting depth of the VIxx Knife Tool The default cutting depth is to cut through the entire material 144 ...

Page 145: ...ting tool rotation and centre offset Remember that you should look at the bottom side of the material for correct alignment The adjustments depend upon the actual material due to weight structure and thickness For optimal result a fine tuning of the adjustments in the actual material should be carried out For more information about how to run the adjustment wizards see Tool Configuration Note On X...

Page 146: ...ter in this position while you turn the tool shaft in order to lock the tool adapter in its position How to set the cutting depth of the VIxx Knife Tool The default cutting depth is to cut through the entire material Define the depth of the bevel cut in the Layer Setup Normally the cut should extend down to just above the bottom liner After a blade change the tool depth should be checked again 146...

Page 147: ...ctual material due to weight structure and thickness For optimal result a fine tuning of the adjustments in the actual material should be carried out For more information about how to run the adjustment wizards see Tool Configuration Note On XL this tool will reduce the work area by approximate 25 mm 1 in in some axes 13 21 VI45 10 12 Knife Tool A knife adapter Lag 0mm 13 21 1 VIxx Knife Tool Moun...

Page 148: ...ade change the tool depth should be checked again About tool adjustment For the VIxx Knife Tool we recommend the manual procedures for tool rotation and centre offset adjustment Use a thin Folding Carton material when adjusting tool rotation and centre offset Remember that you should look at the bottom side of the material for correct alignment The adjustments depend upon the actual material due t...

Page 149: ...13 Kongsberg XL Note On XL this tool will reduce the work area by approximate 25 mm 1 in in some axes 149 ...

Page 150: ...ld be thoroughly cleaned and oiled very lightly The automatic draining action of the air pressure reduction valve should be controlled Switch off the air compressor and allow the air pressure to fall Switch on the air compressor and check that any water in the glass bowl of the pressure reduction valve drains out automatically during the first few seconds of operation Remove and clean the bowl if ...

Page 151: ...U fuses MPU Location Note MPU location is model dependent All fuses are located on the rear side of the Main Power Unit MPU Fuse Location Procedure 1 Remove frame cover in front of MPU 2 Remove the metal shield covering F1 F2 F24 F48 3 Remove one fuse check with ohm meter If blown replace with a new identical fuse 4 Repeat for each fuse 5 Replace base cover 6 Insert main power cable into the wall ...

Page 152: ...fuse T 15A 250V 5x20 mm T 15A 250V 5x20 mm 15 2 X1 fuses X1 Amplifier Location Fuse Location 1 SCU unit 2 6 12A amplifier X1 Procedure 1 Remove X1 cover 2 Check the X1 fuse with ohm meter If blown replace with a new identical fuse 3 Replace covers 4 Insert main power cable into the wall socket and turn main power ON Fuse Details T 8A 250V 1 1 4 x 1 4 in 6 3 x 32 mm 15 3 X2 fuses 152 ...

Page 153: ...over 2 Check the X2 fuse with ohm meter If blown replace with a new identical fuse 3 Replace covers 4 Insert main power cable into the wall socket and turn main power ON Fuse Details T 8A 250V 1 1 4 x 1 4 in 6 3 x 32 mm 15 4 Y Z fuses Y Amplifier Location Fuse Location 1 Y amplifier unit 2 TCU 153 ...

Page 154: ...2 mm Z T 4A 250V 1 1 4 x 1 4 in 6 3 x 32 mm 15 5 Tool Rotation Reciprocating knife fuses Fuse Location Procedure 1 Fuses are available from beneath the Toolhead cover 2 Remove fuse F9 or F10 and check with ohm meter If blown replace with a new identical fuse 3 Insert main power cable into the wall socket and turn main power ON Fuse Details Name Fuse F9 T 2A 250V 1 1 4 x 1 4 in 6 3 x 32 mm F10 T 2A...

Page 155: ... the fan is introduced A For proper operation ensure the ON OFF switch A is in ON position B Correct fuse setting for the fan is B 1 0 A When the Circuit Breaker is triggered The ON OFF switch is in a middle position Find and remove the root cause for the problem Set the ON OFF switch A to ON 155 ...

Page 156: ... Shaking is important in order to maintain a good Vacuum Cleaner performance Filter Shaking is best operated every time before use and after prolonged operation Note This operation must be performed only when the Vacuum Cleaner is switched off and the motor has stopped Remove Material Container 1 156 ...

Page 157: ...ner with or without Plastic Bag Use Plastic Bag in Material Container Parts needed Steel ring and plastic bag Fix the Plastic Bag to the ring in this way Ring and Plastic Bag ready for the container Fold fix the Plastic Bag around the container 157 ...

Page 158: ...rs and maintenance manual 16 2 Vacuum Cleaner High capacity TB ESKO 16 2 1 How to use Introduction 1 Filter Chamber 2 Filter Shaking Lever 3 Removable Material Container Note Carefully observe the Vacuum Cleaner filling level If the Vacuum Cleaner container is filled up completely the dust removal function will stop with a high risk for Spindle Motor damage 158 ...

Page 159: ...aner performance Filter Shaking is best operated every time before use and after prolonged operation Note This operation must be performed only when the Vacuum Cleaner is switched off and the motor has stopped Remove Material Container Note You can use the container with or without Plastic Bag 159 ...

Page 160: ...container Fix the Plastic Bag to the steel bar Plastic Bag with bar ready for container Fold fix the Plastic Bag around the container Container with Plastic Bag ready for operation Detailed information about how to operate the Vacuum Cleaner is available in the Operators and maintenance manual 160 ...

Page 161: ...tube inlet 2 Container fixture 3 Filter unit locking mechanism 4 Motor 5 Filter unit How to empty container 1 Ensure vacuum cleaner motor is off 2 Remove the suction tube 1 3 Release the container 3 4 Remove the filter unit 5 You should have a bucket nearby for the unit 161 ...

Page 162: ...16 Kongsberg XL 5 Lift and turn the container to release it from the fixture 6 Empty the container 162 ...

Page 163: ...17 Kongsberg XL 17 Install Software For information about software installation see the Installation Manual for the actual machine Available on the Documentation DVD 163 ...

Page 164: ... transmitters pointing correctly to their receiver Check if the red light is shining on the receiver If necessary adjust by bending the transmitter receiver holder During start up X1 X2 Y servo error This is probably caused by a defect in an amplifier board Please contact Esko for technical support During start up X1 X2 Y fuse error Check the fuse of the motor If problem persists it is likely to b...

Page 165: ...pindle Is the big green cable still well connected Check all connections of the milling spindle at tool head inside cover X1 and at the inverter Check serial connection between inverter and PC connection OK COM port changed lately If problem still persists contact Esko Milling Communication error Failed to connect to milling controller Try again if the problem persists check COM Port setting and m...

Page 166: ... Try to adjust the force by using the regulator on the spindle vacuum cleaner 18 3 iPC iPC doesn t want to make connection with the machine Make sure you first switch on the machine and then iPC not the other way around If there was a software update recently check if the firmware on the machine and iPC are of the same version Check the serial connection between PC and MCU Check the connection at ...

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