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Esko Kongsberg XP, User Manual

The Esko Kongsberg XP User Manual is available for free download at manualshive.com. This comprehensive manual provides step-by-step instructions, tips, and troubleshooting solutions, enabling users to optimize their experience with the Kongsberg XP. Get the most out of your product by accessing this indispensable manual today.

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17

Kongsberg XP

Add a 3 in. coil on the Autogrip shaft.

Bring the material with the Kongsberg table to
the 

TakeUp Unit 

 till the material is fed far enough

underneath the waste handling kit to reach the
Autogrip shaft.

Take the winding material underneath the dancer
roller and paste it with tape in a straight line onto
the coil.

See picture for the typical loop of the winding
media.

Avoid angular tension in the media; the media will
start telescoping during the winding.

Note: 

 

TakeUp Unit

 should be started only when

material is in place.

Infeed loop

Aligning the media on the Autogrip shaft

17.7.  Start the 

TakeUp Unit

The 

TakeUp Unit

 is activated for processing when:

• The power button is switched on.
• The 

Emergency Stop

 button is pulled up (in de-activated position).

202

Summary of Contents for Kongsberg XP

Page 1: ...Kongsberg XP User Manual 10 2020 XP ...

Page 2: ...ors 16 5 4 Definition of use 17 5 5 Warning sign explanation 17 5 6 Attention areas 20 5 6 1 Mains power disconnection 20 5 6 2 High voltage laser radiation and moving parts 20 5 6 3 Loose clothing 21 5 6 4 Noise level 21 5 6 5 Ejection of parts when milling 21 5 6 6 Milling stop time 21 5 6 7 i Camera strobing light 22 5 7 Safety devices 23 5 7 1 Overview 23 5 7 2 Emergency stop button 23 5 7 3 Ye...

Page 3: ...ain Direction 39 8 7 Vacuum Zone Selection 39 8 8 Job Execution 40 8 9 Corrugated Production 40 8 10 Milling Production 41 8 11 Make a Pen Plot 41 9 How To Procedures Advanced 42 9 1 Optimize vacuum effect 42 9 2 Cutting Thick Materials 43 9 3 Hard Board Production 43 9 4 Multi pass 44 9 5 Job including Reverse Operation 44 9 5 1 Reverse Operation by Left and Right Rulers 46 9 5 2 Reverse Operatio...

Page 4: ...63 11 Tool Configuration and Adjustment 64 11 1 Tool Configuration 64 11 2 Tool Names 66 11 3 Adjust Active Tool 67 11 4 Lag Settings for Rotating Tools 67 11 5 Tool Height Calibration 68 11 6 Rotation Adjustment for Rotating tools 69 11 7 Center Offset Adjustment 70 11 8 Tool Offset 71 11 9 Knife angle calibration 71 11 10 Maintain Tool List 72 12 Tooling System 74 12 1 Introduction 74 12 2 Tool Ha...

Page 5: ...ety issues 115 12 10 4 Precautions 117 12 10 5 Milling advice 121 12 10 6 Cleaner Device 124 12 10 7 Bits and Bit Change 124 12 10 8 Chuck Change and Cleaning 126 12 10 9 Bit Slipping Chuck Change 130 12 10 10 Bit Length and Position 130 12 10 11 Tool Adjustment 131 12 10 12 Table Top and Tool Height Adjustment 131 12 10 13 Miscellaneous 132 12 10 14 LubriCool MultiCUT HP only 133 12 11 Chiller no...

Page 6: ...arts 178 14 Fuse Replacement 179 14 1 MPU fuses 179 14 2 X1 180 14 3 X2 181 14 4 Y 183 14 5 P1 P2 fuses 184 14 6 Fuses on various tools 186 14 7 Chiller fuse Hyfra blue top 187 14 8 Heater for Chiller Fuse 188 14 9 Chiller 2016 Chiller 2020 Fuse replacement 188 14 10 Sound Insulating Box Circuit Breaker for fan 189 14 11 TakeUp Unit Fuse replacement 190 14 12 Motorized Roll Feeder Fuse replacement...

Page 7: ...Vacuum Cleaner 208 20 1 Vacuum Cleaner Zefiro 208 20 1 1 How to use 208 20 2 Vacuum Cleaner High capacity TB ESKO 210 20 2 1 How to use 210 20 3 Compact Vacuum Cleaner 213 20 3 1 How to use 213 21 Install Software 215 22 Frequently Asked Questions 216 22 1 Machine 216 22 2 Tools 216 22 3 iPC 217 vii ...

Page 8: ...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 9: ...formation added 17 03 2018 DHO Motorized Roll Feeder information removed Work area information added 11 05 2018 DHO Operator panel upgrade June September 2018 included misc 19 09 2018 DHO Section for Underside Camera added Reverse operation by use of camera added 30 11 2018 DHO 2nd Fast Tool Enabler for Cx and XP and misc 28 02 2019 DHO Safety precautions updated Feeder Stacker procedures updated ...

Page 10: ...dd mm yy By Description 02 04 2020 DHO Safety section updated 08 06 20 DHO FCC conformity statement added 14 09 2020 DHO Minor update 22 09 2020 DHO Warning sign Sharp knives added 27 10 2020 DHO VariAngle unit included 10 ...

Page 11: ...l 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 2 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 subject...

Page 12: ...ow 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 Creasing or Milling how to Jobs including Reverse Operations how to Work with different Reference Point Settings how to MultiZone Production how to Work with Registration Marks A step by step workflow S...

Page 13: ...tton Start button The italic style indicates this is a button on the Operator Panel OK The bold style indicates this is a button or function in the GUI Maintenance Link 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 indicat...

Page 14: ...ngsberg XP 4 4 Local Languages This manual is available in a wide range of local languages Screen pictures and illustrations remain in English language For safety related illustrations text is translated 14 ...

Page 15: ...l when operating the milling tool The milling spindle needs a few seconds to stop and any contact with a rotating milling bit is very dangerous Use appropriate techniques and tools when handling heavy materials The machine has fast moving parts like the traverse and tool head Stay away from the danger zone during operation The system is equipped with a class II laser pointer Do not stare directly ...

Page 16: ...d and understood the instructions described in safety regulation as well as any other safety warnings Training will be given to operator s nominated by the customer by the Esko service engineer as part of the system installation The training covers Safety regulations Start up and shut down procedures Online help user manuals Set up procedures Adjustment procedures Workflow Maintenance For additiona...

Page 17: ...oid detection Utilizing accessories other than those specified by Esko Operating or maintaining the machine or any of its accessories under the influence of drugs alcohol or medication that could impair your judgment and vigilance Non intended use may cause Health hazards and injuries Damage to the system Incorrect functionality Damage to work materials Note Esko is not liable for any damage resulti...

Page 18: ...ution laser 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 materia...

Page 19: ...areas 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 ...

Page 20: ... station is intended for daily power on off To permanently disconnect mains power e g for maintenance use a lockable on off switch at the power line if available or remove the plug from the wall outlet In addition turn off the main power switch Note A lockable on off switch on the power line may be required by local regulations but is part of the site preparation site owner s responsibility not in...

Page 21: ...xposed to the noise from the machine This is particularly recommended during milling operation or when using reciprocating tools The noise level heavily depends on the material that is processed 5 6 5 Ejection of parts when milling Eye protection must always be used to prevent injury from potential risk of breaking milling bits or pieces of processed material See also Safety issues on page 115 in ...

Page 22: ...ling 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 amongst susceptible people If a person is known to be susceptible the frame rate frequency of strobing can be reduced to as low as 1 Hz from t...

Page 23: ...berg XP 5 7 Safety devices 5 7 1 Overview 5 7 2 Emergency stop button Emergency stop buttons Switch positions OUT Normal operation enabled IN Emergency stop active Servo power to the machine is switched off 23 ...

Page 24: ...e Servo on pushbutton 4 Observe that servo power is switched on 5 Press Start to continue 5 7 3 Yellow black tape The yellow black tape indicates the attention area This area is restricted to operators and other trained personnel 5 7 4 Warning lamps on Y carriage Light is Description Y carriage Off Servo power is off On Servo power is on DynaGuard safety system is enabled table is ready for operat...

Page 25: ...front to prevent squeeze risk A deflective stop mechanism mounted on each end of the traverse Machine movement will stop and servo power will be switched off if One of the light beams is broken The stop mechanism is activated Continue operation To continue operation after the DynaGuard safety system system has been activated do 1 Ensure the table is free from obstructions and ready for operation 2 ...

Page 26: ...the operators Esko recommends the following protective equipment Close fitting clothes to avoid being caught by the beam or the tool head which can cause injuries Gloves to protect against cuts from materials with sharp edges Eye protection must be used by any personnel working with milling Always use hearing protection when working with the machine for a longer period of time The acoustic noise le...

Page 27: ...ning lamp functioning Electrical parts and connections without excessive moisture Tools properly fastened Vacuum cleaner not full Emergency buttons unobstructed Operator has proper training 5 11 Residual risks Despite all safety protection means incorporated in this machine there are some residual safety risks to be aware of Beneath traverse end The lower part of the traverse end is un protected A...

Page 28: ... all machine motions as fast as possible when interrupted by a body part or other object When the feeder bar or feeder paws illustration are mounted the distance between the rear beam and the mechanics is reduced Actions Stay out of this area while the machine is operating Inside cable chain There is a risk for squeezing between the cable chain and the table frame Actions Stay out of this area whi...

Page 29: ...s and considered non intended use Touching the milling bit while rotating Stop time of the milling spindle is up to 4 seconds This is su cient time to access and touch the milling bit before it has come to a complete stop It is crucial that the operator always ensures by visual inspection that the milling bit has come to a complete standstill before touching it 29 ...

Page 30: ...g Conventions Machine 1 Cutting Table 5 Main Power on off switch 2 Tools 6 Operator Panel 3 Y carriage 7 Emergency Stop button 4 Traverse 8 Main Power Unit MPU Axes X X axis P1 P1 Tool Position Y Y axis P2 P2 Tool Position X1 X1 end of traverse 30 ...

Page 31: ...e Main Power Switch is located on the Operator Station Switch positions O Main Power to the machine is switched OFF I Main Power to the machine is switched ON 6 3 Operators Panel Power On Mains Power on off indication Servo Power On Servo Power on off control 31 ...

Page 32: ...ble 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 Zero movement is completed Jog buttons Press the Jog buttons to move the tool head in the desired direction The system must be in Pause mode i e the Pause button must be lit for these butto...

Page 33: ...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 High Pressure Air System General The High Pressure Air System supplies the valves and tooling with compressed air The compressed air input is connected to a combined Pressure Regulator Valve Water Trap Wall Outlet Wall Outlet A Air T...

Page 34: ...ressure level Execution will stop An error message is displayed 6 5 Application Programs Available After installation of iPC the following application programs are available iPC Control program for the Cutting Table For more information see User Manual for i cut Production Console SysLoad Program for download of updates to CU modules HWT900XP Hardware test program see separate HWT900XP User Manual...

Page 35: ...sed upon the following assumptions The User Interface is up and running The actual Tools are properly mounted and adjusted 7 2 Power On Sequence Ensure the table is free from obstructions and ready for operation Follow these steps to 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 pow...

Page 36: ... will move to the Selected Reference Point 7 The table is now ready for operation 7 3 Reset Safety System Press Pause to Reset Safety System 7 4 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 After power off wait minimum 5 sec before the system is swit...

Page 37: ...Lamp 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 37 ...

Page 38: ...ng 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 Create Job In My Jobs List double click a file My Job Actions Create Job...

Page 39: ...Position Step and Repeat Registration Material Handling Tool Head Parking 8 5 Speed Setting Opened Job Production Setup Quality Specify if this is a High Accuracy or a High Speed Job 8 6 Flute Grain Direction Properties Bar Flute Grain Direction Verify that the Flute Grain Direction corresponds to the material 8 7 Vacuum Zone Selection Machine Panel Toolbar Vacuum Zones 39 ...

Page 40: ...Table View display of the Job is reasonable 3 Press Pause to reset 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 9 Corru...

Page 41: ...g the procedure described in the Prepare for a Job chapter Recommended tooling is described in Esko Tooling Guide Note Milling Jobs should be executed in High Quality mode 8 11 Make a Pen Plot Pen Plot without Registration Marks is straight forward following the procedure described in the Prepare for a Job chapter Ensure the Ballpoint Pen is clean and ready to use 41 ...

Page 42: ...he material Machine Panel Toolbar Vacuum Zones or use Intelligent vacuum control Ensure that material and job are placed across a minimum number of vacuum zones In the leftmost picture all vacuum zones need to be open If moving the material to the right two of the zones can be closed and material hold down is imporved Open parts of the vacuum zones can be covered to improve the material hold down ...

Page 43: ...bed in the Prepare for a Job chapter Cutting Depth when Depth Referenced from Top is disabled Note This function is useful for all materials with an un even surface 9 3 Hard Board Production To prepare hard board materials the procedure is as follows 1 Mill through the top layer using HPMU 2 Cut through the mid section using the MP HF VibraCut Knife 3 Mill through the bottom layer using HPMU Ensur...

Page 44: ... or milling is available by modifications in the Opened Job Layer structure Proceed as follows 1 Identify the Layer containing the crease or milling line s where Multi pass is wanted 2 Make one or more copies of the Layer including geometry 3 The Layers will be executed in the listed sequence 4 In the Layers update the depth values to suitable steps For execution follow the procedure described in t...

Page 45: ... Configure Tools Reverse Operation can also be controlled from a button in Layers Tab Status 1 Selected 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 45 ...

Page 46: ...e sheet flipped and aligned towards the Left Ruler The rest of the Job is completed A typical use of Reverse Operation is when 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 5 2 Reverse O...

Page 47: ...hat all layers except the regmark layer must be processed from the reverse side The function requires that the table is equipped with a Tool Head with Camera and that the job has Regmarks 9 5 3 Reverse Operation in combination 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 ...

Page 48: ...corners 9 6 Work with different Reference Point Settings Select the Reference Point to use from Opened Job Production Setup Position Reference Point For more information go here 9 7 MultiZone Production Introduction In User Manual for i cut Production Console general information about MultiZone Production is available In this chapter XP specific issues are described 48 ...

Page 49: ...um on Button 4 Vacuum Lamp Vacuum Zones Vacuum Zone Configuration on page 60 MultiZones The illustration shows the most actual zones available for MultiZone Production Limitations Work Areas on a MultiZone table A standard Cutting Table prepared for MultiZone Production has a limitation caused by the size of the last section as can be seen by the illustration SeeWork Area table below 49 ...

Page 50: ... in 2210x3200 87x126 3210x1600 126 37x63 3210x3200 126 37x126 3210x4800 126 37x189 Work area MultiZone Production standard tabletop mm in 1680x1450 66x57 2210x1450 87x57 N A 3210x1420 126x56 3210x2210 126x87 9 7 1 MultiZone Workflow Recommended material flow direction 50 ...

Page 51: ...other zone photo cell beams traverse end cover To ensure a continous workflow the operator should be very careful inside the Attention Area not to trigger the safety system by his body or by material in and out Thus we recommend loading and unloading material from the front and back end of the table 51 ...

Page 52: ...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 3 Adjust Measuring Station Position 4 Set Ruler Position 5 Set Main Reference Point 6 Map Table Top Surface 7 Calibrate Foot on Measuring Station...

Page 53: ...s Typical use is after maintenance or repair Procedure 1 Execute the Adjust X1 to 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...

Page 54: ...he Measuring Station 10 5 Set Ruler Position Machine Connection Machine Configuration Installation_ Set Ruler Position Follow instructions from the wizard If your table is equipped with Rulers please complete the wizard for Left and Right Ruler For the table to operate properly an exact registration of the Ruler Positions is necessary This is a one time job but it can be necessary to repeat the pro...

Page 55: ...Map Table Top Surface Machine Connection Machine Configuration Installation_ Map Table Top Surface To assure correct Cutting Depth the surface of the Table Top is measured in order to create a map It is recommended to execute this function if the Cutting Mat is worn out and after the Cutting Mat has been replaced Procedure 1 If the table is equipped with a Conveyor Belt move the belt junction away ...

Page 56: ...setting is available to enable the old behavior 10 8 Calibrate Foot on Measuring Station Machine Connection Machine Configuration Installation_ Calibrate Measuring Pad Use this wizard to calibrate the height level of the Measuring Station Typical use is after maintenance or repair to ensure the tool height measuring system works properly Procedure 1 Press the Calibrate Foot 2 Follow the instruction...

Page 57: ...ioned in order to obtain A full Work Area Correct Sheet Feed operation Correct handling of Long Jobs Using the Main Reference Point during program execution ensures correct operation User Defined Reference Points You can specify User Defined Reference Points User Defined Reference Points are used if you want your job positioned in a fixed position on the table Rx but not in the Main Reference Point R ...

Page 58: ...0 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 same time the direction of the X axis is reversed 10 10 Table Speed Menu Bar Advanced Configure Tools Velocity X Y This is the default value fo...

Page 59: ...for this particular Job 10 12 Jog Settings Continuous Jog speed The Continuous Jog Speed can be reduced 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 ...

Page 60: ...ulation The Table Top Reference function should be carried out After mechanical adjustments of traverse or tool head When cutting through material is not working properly After any change of cutting milling underlay for instance after adding or removing the milling underlay Procedure 1 Remove all materials from the table surface 2 Measure on top of the cutting underlay or conveyor belt 3 If the ta...

Page 61: ...s a one time job as long as the Vacuum Zone Solution on the machine remains unchanged The setup should correspond to the actual hardware The selected setup will determine which Vacuum Zone Configuration that will be available in the User Interface Machine Zone Configuration Vacuum Configuration XP20 7 XP24 2 XP44 2 61 ...

Page 62: ...d Note The control unit needs to be connected to a genuine COM port If connected to a USB to COM adapter the communication will fail These functions are used only after a hardware modification 10 16 Conveyor Belt Control Machine Connection Machine Configuration HW Configuration Conveyor Specify if the machine is equipped with Conveyor Belt 10 16 1 Split Sheet Feed Sheet in Load Position Sheet Load st...

Page 63: ...rg XP 10 16 2 Sheet Feed Correction If the Conveyor Belt feed length needs adjustment use this function to adjust the movement of the Conveyor Belt to be shorter or longer 10 17 Board Size Not implemented yet 63 ...

Page 64: ... all tool settings and adjustments Select tool and function 11 1 Tool Configuration The XP machine offers two different tool positions P1 and P2 where different interchangeable tools can be mounted In addition there are separate fixtures for Laser Pointer Measuring Foot Camera Drill and Pen Tools L Laser Pointer M Measuring Foot 64 ...

Page 65: ...HD Crease V notch Knife HD Knife Tool Bevel knife Perforation Wheel Yes VariAngle unit Standard adapter and long adapter for short knife blades optional Yes FCU Foam Cutting Unit Yes HPMU High Power Milling Unit Yes VibraCut Knife Tool Yes HF VibraCut Knife Tool Yes Yes HiForce Knife Tool Yes RM Knife Tool Yes RotaCut Knife Tool Yes PressCut Yes Psaligraphy knife tool Yes CorruSpeed knife tool Yes...

Page 66: ...ool can not be used with the Fast Tool Adapter fits in P2 only 11 2 Tool Names Factory Tool Name The Tool Type mounted is identified by hardware codes inside each tool The identified tool is called Factory Tool Name The mounted tools are maintained by Machine Connection Tool Configuration Current tool configuration is displayed under Identified tools When a new tool is inserted it will be identified to t...

Page 67: ... the adjustments Note All tools need to be adjusted in the position they will be used Before any adjustment complete a Table Top Reference function 11 4 Lag Settings for Rotating Tools Machine Connection Tool configuration Adjust Active Tool Lag Settings Follow instructions from the wizard 1 In the Configure Tool dialog select the Tool to be adjusted 2 Press theAdjust Active Tool button to enter the...

Page 68: ...ctive Tool Tool Height Calibration Follow instructions from the wizard C systems are equipped with Automatic Tool Height Calibration Thus the system will run without any manual height calibration If you would like to add an offset to the measured height use the Tool Height Calibration dialog 1 Select the Tool to be adjusted 2 Press the Adjust Active Tool button to enter the wizard selection dialog...

Page 69: ...Adjust Active Tool Manual Adjustment of Follow instructions from the wizard 1 Place an appropriate test material on the table and switch Vacuum On 2 From Machine Connection Tool Configuration select one Tool 3 Press Adjust Active Tool to enter the Wizard Selection Dialog 4 Select Manual Adjustment of Center Offset and Angle 5 Enter value for the Angular Offset and select Activate 6 Note that the To...

Page 70: ...witch vacuum on 2 Select the Tool to be adjusted 3 Press the Adjust Active tool button to enter the wizard selection dialog 4 Select Center Offset Adjustment 5 Follow the instructions given by the wizard step by step 6 Repeat the procedure for all Tools mounted Manual Adjustment Machine Connection Tool configuration Adjust Active Tool Manual Adjustment of Follow instructions from the wizard 1 Place...

Page 71: ...e an appropriate test material on the table and switch Vacuum On 2 From Machine Connection Tool Configuration select one Tool 3 Press Adjust Active Tool to enter the Wizard Selection Dialog 4 Select Offset Adjustment 5 A cross is made by the Tool to be adjusted 6 The Laser Pointer is positioned in the center of the cross 7 If necessary jog the Laser Spot into the center of the cross 8 Follow the in...

Page 72: ...en click Next 4 Go to the notch angle area 5 Enter a positive or negative value in the Zero Offset degrees box or use the up down arrows 6 Click Activate and then Finish to store the offset 11 10 Maintain Tool List Machine Connection Configure Tools 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 To...

Page 73: ...hen a Tool is no longer in use The deleted Tool will no longer be available in the Tool List in the Edit Layer dialog Add Tool Use Add Tool to Add new Tools Add tools that fails during Automatic Tool Detection The Tool is added to the Tool List 73 ...

Page 74: ...all tools are explored General description How to operate How to adjust 12 2 Tool Handling and Care All Tools are precision instruments and should be treated as such to ensure proper operation Take special care when Tools are inserted 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 temp...

Page 75: ...ed 12 4 Two or more tools of the same type Each tool is identified to the system by Tool Type In addition it is possible to identify up to four different tools of the same type One example If you have two different Static Knife Tools you can specify one to be number 1 and one to be number 2 In this way all Adjustment Parameters will be stored and recalled automatically as the tool is mounted onto t...

Page 76: ... Tool Numbers The different Tool Numbers are defined as follows Tool Number Tool Board switch setting Tool 1 1 2 off Tool 2 1 on 2 off Tool 3 1 off 2 on Tool 4 1 2 on Note There are some restrictions see Technical Manual for more information 12 5 Measuring Station XP is equipped with a Measuring Station 76 ...

Page 77: ...y Tool change and the Tool is not calibrated After the Safety System has been broken for 30 sec or more After the Servo System has been off for 30 sec or more During the Table Zero Sequence if Incremental Jog is selected Tool Depth and Measuring Station Be aware how the Measuring Station is working it is the tool tip that is measured Depending upon the actual tool it might be necessary to add dept...

Page 78: ...e separate chapters for V notch Knife HD knife tools ø150 mm Crease Wheels Crease Adapter Perforation Wheel ø60 mm 12 6 1 Crease Wheel ø150 mm Description A ø150 mm Crease Wheel mounted on an Heavy Duty Unit This Crease Wheel has the equivalent of 50 kg 110 lbs of down pressure The additional pressure combined with the large frontal area of the big wheel enables excellent crease quality in heavy d...

Page 79: ...ents Adjustment Description Lag Setting The Lag value depends upon the Blade Adapter Nominal value is 0 mm Tool Height Measured automatically possible to add an Offset Value 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 ...

Page 80: ...ife Tool Description The V notch Knife Tool mounted on a Heavy Duty Unit How to insert remove the V notch Knife Tool i 1 Turn the V notch Knife Tool correctly to fit the Guide Pin 2 Insert the two Latch Pins 3 Insert the Cotter Pins 80 ...

Page 81: ...commend the manual procedures for Tool Rotation and Center Offset adjustment When adjusting Tool Rotation and Center Offset use a thin Folding Carton material Remember that you should look at the bottom side of the material for correct alignment The adjustment depends upon the actual material due to weight structure and thickness For optimal result a fine tuning of the adjustments in the actual mat...

Page 82: ... the entire material 2 To make adjustment to the depth go to Opened Job Edit Layer 3 Normally the cut should extend down to just above the Bottom Liner V notch Knife Cut Direction The blade angle and the cut direction must be taken into account when cut jobs are prepared The arrow indicates the Cut Direction Different angles A wide range of V notch knives is available providing different knife ang...

Page 83: ...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 V notc...

Page 84: ... to ease removal of waste Note This function is working along Y only Flute direction must be along Y The numbers indicate sequence of operation 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 Adjust the cutting widt...

Page 85: ...s used to ensure a nice folding result Waste Cut function adjustment This illustration shows a typical use of Waste Cut function The middle wall is not cut by 2 or 3 making the material impossible to fold The Waste Cut function 1 cut the middle wall and you can fold the material nicely Negative and positive adjustment direction vs cut direction 12 6 3 HD Knife Tool Description The HD Knife Tool mo...

Page 86: ...al The Tool is limited to Straight Lines longer than 50mm 2 The Tool is prepared for special trapezoid shaped Knife Blades How to replace a Knife Blade Warning Sharp tool This picture shows how the Knife Blade is aligned against two Guide Pins Use these two screws to fix release the Knife Blade 86 ...

Page 87: ...djustment Description Lag Setting The Knife Lag depends upon the Blade Adapter Nominal value is 10 mm Tool Height Measured automatically possible to add an Offset Value 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 t...

Page 88: ...s in HDU by using two Latch pins with accompanying cotter pins 12 6 5 Perforation Wheel ø60 mm Use Perforation Wheel to prepare Perforation Cut Lines or to assist creasing at high speed Perforation wheels with different pit to land ratios are suitable for multiple purposes in different materials Before August 2019 Esko s portfolio of Perforation wheels had four different sizes 3 3 mm 5 5 mm 7 5 mm...

Page 89: ...12 Kongsberg XP Perforation Wheel assembly Warning Sharp tool Parts in assembly Ensure the path is clean Fix cover properly Push pull the Perforation Wheel in out from the 60 mm crease adapter 89 ...

Page 90: ...ntial to Moving Direction Center Offset Adjust Tool sideways until centered Tool Offset Adjust offset relative to Laser Pointer Tip When adjusting Tool Height for Perforation wheels or Crease wheels move the tool outside of the material surface Set the Tool Height so that the Tool tip touches the Table Top Surface before manually jogging the tool through the material Complete wizard and inspect cr...

Page 91: ...bevel cut in the Layer Setup Normally the cut should extend down to just above the bottom liner About tool adjustment For the Bevel Knife 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 adjustm...

Page 92: ...nife Tool when not in use If the Tool Head is left on a table surface the Knife Blade might be exposed as the material hold down wheels moves up How to replace a Knife Blade Warning Sharp tool Loosen the fixing screw replace the Knife Blade and fix it again No additional adjustments are necessary as the tool height is measured automatically 92 ...

Page 93: ...Measurement Opened Job Layers Edit Layer For the Foam Knife Tool the Disable Material Thickness Measurement function is available Use this function if 1 Your foam material is too soft for the measuring system 2 The surface of your material is un even When the Disable Material Thickness Measurement function is enabled the following rules applies Depth is referenced from bottom top of cutting underl...

Page 94: ...t offset relative to Laser Pointer For more information about how to run the Adjustment Wizards see the Tool Configuration chapter 12 8 Dual HDU Dual Heavy Duty Unit P1 P1 tool positions see table below P2 P2 tool position see table below C Camera Position P Pen Drill Ink Tool holder position P1 1 Position 1 of the Dual HDU equal to the standard HDU P1 4 The secondary position of the Dual HDU and t...

Page 95: ...ngles N A Cannot combine V notch with 2nd tooling position For detailed descriptions of the P1 1 tooling inserts see separate section for HDU Heavy Duty Unit V notch Knife 150 mm Crease Wheels Crease Adapter Perforation Wheels Bevel Knife For detailed description of P1 4 and the new method for mounting dismounting tools see separate sections below Dual HDU HD Perf Position on page 96 New mounting ...

Page 96: ...cut depths up to 6 mm This position was developed to deliver additional flexibility and to allow creasing and perforating heavy duty materials with the use of one tool unit Perforation Wheel mounting for the Dual HDU The Perforation Wheels are locked in place using a Locking screw when mounted in the HD Perf position This is to ensure that the wheel is not pulled out when converting heavy materials...

Page 97: ...justments Adjustment Description Lag setting The nominal value for Perforation Wheels is 0 mm Note The lag value can be used to adjust overshoot and Lead in of Perforation Cut Lines Tool Height Measured automatically as separate tool It is possible to add an Offset value Note Height measurement of Perforation Wheels on the Measuring Station depends on the orientation of the wheel pit or land facin...

Page 98: ...ng connected to the main Dual HDU structure The HD Perf position is not compatible with V Notch Knife Tool or HD30 knife The HD Perf position will automatically be disabled from SW if one of these tools are identified in tooling position P1 1 The tool mounted in the HD Perf position must be removed before inserting a V Notch Knife Tool in position P1 1 will not fit if not 12 8 2 New mounting procedu...

Page 99: ...ols with Perforation Wheel still mounted HD Knife tool safety cover The HD Knife tools come with an additional safety cover If you have bought a HD Knife Tool before Q3 2019 the axle bar that holds this safety cover must be exchanged if you want to use your HD Knife Tool in the Dual HDU Find the new axle bar attached to your Dual HDU kit 99 ...

Page 100: ...position P1 on Cxx and XP platform It is specially prepared to cut at different angles also known as V notching The tool can automatically change the angle of the knife between 0 and 60 degrees in 0 5 degree steps where 0 degrees is vertical 12 9 2 Safety precautions Warning Sharp tool 100 ...

Page 101: ...ive and another tool is selected In the case of the tool being selected while the machine is not running a job the knife will point straight down towards the table Note Never put your hand close to the tool while the tool is moving 12 9 3 Tool description 1 Knife blade for cutting of thicker board materials There are different blade lengths that fit different adapters 2 Adapter The adapter is fixed ...

Page 102: ...For safety reason always mount the tool to the machine before mounting adapter with knife blade And further Always remove the adapter with knife blade before dismounting the tool from the machine Warning Sharp tool 12 9 4 Description of knife blade adapters The knife blade adapter comes in two versions standard adapter for standard long knife blades and an optional long adapter for short knife bla...

Page 103: ...erfect results in thicknesses of 5 10 mm 0 2 0 39 in Straight cut up to 16 mm 0 63 in material thickness V notch cut at 45 degrees up to 13 mm 0 51 in thickness V notch cut at 60 degrees up to 6 mm 0 24 in thickness The table describes the limitations for the two adapters with regard to material thickness and notch angle Orange Standard adapter with standard long knife blades Green Long adapter wi...

Page 104: ...t first time use It can also be re calibrated by wizard Lag setting The nominal value for the Standard adapter is 19 mm 0 75 in The optional long adapter for short knife blades has a nominal value of 9 7 mm 0 38 in Note The Lag setting can be used to adjust overshoot and lead in of cutting lines Tool Height This is measured automatically It is possible to add an offset value Note In the Tool Height...

Page 105: ...rom the Job window or create a new material with a thickness from Advanced Resources My materials Opened Job Layers Tab Edit Layer Menu Bar Layer Edit Layer In the Edit Layer dialog the cutting preferences can be set up Notch angle can be set to any angle between 0 and 60 degrees New and old terms V notch cut replaces Single Cut V notch Crease replaces Double Cut Waste Cut replaces Triple Cut Widt...

Page 106: ...shall cut Normally a depth that leaves the bottom liner is specified The illustration above shows typical examples of relation between notch angle and folding angle The formula to calculate it is Folding angle 180 degrees 2 x notch angle When the depth of a V notch Crease is reduced the distance between the two cuts in the bottom will increase The Width Offset function can be used to adjust the wid...

Page 107: ...ch angle To remove the waste of a V notch Crease that is still connected to the board the Waste Cut function can be enables This function adds a third cut to the line at specified distance from the second cut 12 9 7 Workflows set up and optimization Please use references and links below for different resources Workflow iPC manual section Optimal Production Workflow Get the best out of iPC manual Engli...

Page 108: ...m the back the Reverse Operation function can be used see Job including Reverse Operation on page 44 Knife Overcut The Knife Overcut function will add length to the start and or end of all lines within a layer Note that because of the width of the VariAngle blades there might be a substantial difference between line lengths on top and bottom of the material By default the system will expect that t...

Page 109: ...ar geometries If the radius is too small or the board material too tough it might cause the blade to break or the knife to cut into the table top There is no warning for minimum radius as this will be material and notch angle dependent It is highly recommended to reduce speed and acceleration when cutting arcs and curves To increase the quality of the circular cuts the Circle Adjustment setting ca...

Page 110: ...nu The knife blade can be compensated between 3 and 0 degrees Multi pass Using multi pass as for milling can be a good choise for challenging materials when cutting at an angle The recommended method is to use two passes In the first pass cut down to the bottom liner in the second pass cut through the bottom liner This can either be done by copying the cutting layers and assigning different cutting...

Page 111: ... is also the case if more depth is added to the cut to get through See section Multi pass on page 44 More about multi pass in user manual for iPC 12 9 9 Work area limitations Due to the design of the VariAngle unit the work area of the cutting table will in some cases be reduced The reduction depends on the table size notch angle thickness of the material and cutting direction The work area will o...

Page 112: ...the edges The amount needed is material dependant and might also be dependant of the cut direction Ensure that the knife blade is clean Note Glue might sometimes stick to it 12 10 HPMU High Power Milling Unit 12 10 1 Introduction Spindle motor Power rating max 3 kW Cooling system Liquid cooling Shank size max 8 mm RPM max 60000 Tool change Pneumatic Vibration sensor board No HPMU chucks Different ...

Page 113: ... 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 milling bit cooling and to ease chip removal Adjust for proper operation 3 Chuck Open Close The shown position is closed Note To protect the chuck from damage and the spindle from contamination do not ...

Page 114: ...on is available on the gallows stand Use the park position for safe HPMU Tool Head storage Note For safety reasons always insert a Dummy Bit when parking Chiller HPMU start up time Depending upon the environmental temperature the Chiller needs some start up time after Power On before it is ready to operate Typical delay is 2 3 minutes 114 ...

Page 115: ...tion If you are using short 8 mm bit these must be limited manually to 40 000 RPM In general 6 mm bits are preferable in materials up to 20 25 mm thickness 12 10 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 vac...

Page 116: ...n 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 protection must be used by any personnel working with milling Always use eye protection when working with milling Hearing protection The noise generated by milling varies with the material bei...

Page 117: ...hine 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 Be aware it is normal that the HPMU becomes hot during operation Clean surface Keep the table and material surfaces clean free from obstacles 12 10 4 Precautions Follow these precautions to take care of the milling...

Page 118: ...ctual 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 40 000 HPMU Keep distance d small For best per...

Page 119: ...dle is sensitive for the Pressurized Air quality Regularly check the Air Pressure Reduction Valve according to the Maintenance Description 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 Clean the bit shaft with acetone if necessary but use only dry cotton tips on the chuck 4 Maintain Pr...

Page 120: ... of operation and is di cult 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 Empty Vacuum Cleaner in time 1 Do not leave the ma...

Page 121: ... advice Follow this advice for obtaining the best possible milling results Milling Bits For thin materials use bits with short cutting length For best performance and minimum wear do not let the bit stick out more than necessary 121 ...

Page 122: ...r 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 HPMU 60 000 Milling bit edges are brittle Never let bits touch each other or other hard surfaces Always store in proper container Acrylic Bits or Multi Purpose Bits 1 Acrylic Bits A are polished extra sharp for acrylic wood etc 2 Multi Purpose Bits MP have a higher wear resistance and are ...

Page 123: ...er bits Worn bits increase the Power Consumption Number of Passes in Thick Materials The Number of Passes depends on Material Type Milling Depth and Bit Diameter Use a Pass Depth that makes the groove free of chips normally that is a depth equal to the Milling Diameter Material Hold Down Material Hold Down may be a limiting factor Small parts cut loose can be a problem This can be done to improve ...

Page 124: ...a Cleaner Device which is available as an option 12 10 7 Bits and Bit Change How to insert replace a milling bit Warning Sharp tool 1 Ensure the Spindle is not running and that the red light is off Mind the sharp bit and move the Suction House up Lock the house in its up position 124 ...

Page 125: ...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 chapter for more information 4 Release the Lock to allow the Suction House moving down to its down position 125 ...

Page 126: ... Valve or the Pressurized Air source If the bit is still stuck see the Chuck change and cleaning section about how to unscrew the chuck 12 10 8 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 impact...

Page 127: ...the chuck and remove any bit Note Never apply 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 127 ...

Page 128: ...unscrew the chuck using the Chuck Tool If the bit is stuck hold the rotor with the 17 mm key and unscrew with a 12 mm key Note Tool Open must be pressurized 5 Use the Taper Brush to clean the Taper 6 Push the Air Clean Button to help remove contamination 128 ...

Page 129: ...lamping force 8 Apply small quantities of grease to the threads of the chuck and to the outer cone and cylindric surface of the chuck green 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 12...

Page 130: ...iately if you experience any problems as 1 Bit slipping 2 Bit vibrations When replacing the chuck follow instructions in Chuck Change and Cleaning on page 126 New chucks are available from Esko store 12 10 10 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 130...

Page 131: ...djustment Description Tool Height Measured automatically possible to add an Offset Value Tool Offset Adjust offset relative to Laser Pointer For more information about how to run the Adjustment Wizards see the Tool Configuration chapter Notes regarding Tool Height adjustment When properly adjusted the milling bit should barely touch the top surface of the material 12 10 12 Table Top and Tool Height...

Page 132: ...the cutting underlay Thus it is not possible to mill through the material in this case Tool Height will follow the mapped tabletop Milling Underlay U on top of the Cutting Underlay To be able to mill through the material the thickness of the Milling Underlay must be 2 mm 0 08 inch Tool Height will follow the mapped tabletop 12 10 13 Miscellaneous Warm Up Machine Panel Toolbar Warm Up To protect th...

Page 133: ...contact with the debris 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 speed zero depth and maximum feed Insert the Dummy Bit into the chuck Adjust the brush height until...

Page 134: ...ection window B Suction cup with nozzles LubriCool control unit How to use LubriCool is on when the Vacuum Cleaner is on For materials where lubrication is not suitable use the ON OFF switch on the LubriCool Control Unit to switch off lubrication 134 ...

Page 135: ...nspection Opening When the LubriCool unit is on you can see light in the control relays inside the unit Oil For LubriCool use this oil only Accu Lube LB 5000 Use Nozzle Unit or Suction Ring Nozzle Unit Suction Ring 135 ...

Page 136: ... materials especially MDF use the Suction Ring Note It is crucial for proper operation that these guidelines are followed How to interchange the Nozzle Unit Suction Ring Cleaning Proper cleaning is crucial for correct operation Release locker A and remove the nozzle unit Use vacuum cleaner to clean the HPMU suction house Use vacuum cleaner to clean the nozzle unit 12 11 Chiller no 1 blue top for H...

Page 137: ...per operation the flow level should be 1 0 l min 12 11 2 Chiller Heater Operation Notes 1 The Chiller Heater is optional 2 The Chiller Heater must be filled with water before connecting mains 3 The Chiller Heater is correctly configured when shipped from the factory Normally there is no need for modifications Some operating instructions are included here if any modifications are still needed 137 ...

Page 138: ... elements 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 F...

Page 139: ...ow Liquid flow too low less than 0 5 l min The signal is 1 minute delayed Temperature sensor failure If any chiller failure occurs you have to look at the chiller display to see the real reason for the problem Code Description E0 Sensor 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 ...

Page 140: ...30 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 Filled with liquid 33 kg 73 lbs Chiller 2020 Internal heater Both these models are equipped with internal automatic heater Chiller Unit 12 12 2 Startup Ensure the following pre requisites ar...

Page 141: ...er level too low Liquid flow too low less than 0 8 l min The signal is 1 minute delayed to be able to fill water hoses at startup During normal operation the cooling medium temperature is displayed If any chiller failure occurs Alarm signal is generated Chiller will stop Look at the chiller display to see the real reason for the problem Code Description AL Water level or water flow too low Check for ...

Page 142: ...is recommended for light duty Corrugated Materials HF VibraCut High Frequency VibraCut Running with 12000 RPM and amplitude 0 6 mm 0 024 inches this tool is recommended for more demanding Corrugated Materials Note Hearing Protection is recommended when working with this tool Common to both models To reduce material tear a foot is available The same set of Knife Adapters can be used Replace Knife B...

Page 143: ...tion relative to the screw Push the Knife Blade down while the screw is fixed Extreme care should be taken when inserting the Knife Foot again Keep fingers away from Knife Blade as illustrated at left Tool Adjustment For this tool complete the following adjustments Adjustment Description Lag Setting The Knife Lag depends upon the Blade Adapter 143 ...

Page 144: ... 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 14 Rigid Material Knife RM Knife Tool Replace Knife Blade Warning Sharp tool Use a 3 mm Allen key to fix loosen the Knife Blade 144 ...

Page 145: ...lade Adapter Nominal value is 0 4 mm Tool Height Measured automatically possible to add an Offset Value 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 15 HiForce Knife HiForce Knife is...

Page 146: ...es To reduce material tear and also to keep the material down as the Knife Blade is pulled out a Knife Foot is available Replace Knife Blade Warning Sharp tool Pull straight out to remove the Knife Foot Loosen the screw A and replace the Knife Blade Ensure the Knife Blade has correct position relative to the screw Push the Knife Blade down while the screw is fixed 146 ...

Page 147: ... upon the Blade Adapter Nominal value is 0 3 mm Tool Height Measured automatically possible to add an Offset Value 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 Replace Knife Adapter To ...

Page 148: ...a tool for cutting of fine details in paper and folding carton Replace Knife Blade Warning Sharp tool 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 Tool Adjustment For this tool complete the following adjustments 148 ...

Page 149: ...st offset relative to Laser Pointer For more information about how to run the Adjustment Wizards see the Tool Configuration chapter 12 17 PressCut PressCut is a special knife tool for vinyl cutting The Cutting Depth is controlled by the downward knife pressure The pressure is adjustable from Opened Job Edit Layer dialog For applications where a more accurate depth control is required a simple foot ...

Page 150: ...hen removing and inserting Knife Blades into the tool When inserting a new Knife Blade ensure the blade is correctly positioned relative to the Alignment Pin Configure Tools Tool Pressure PressCut can run with a Constant Tool Pressure or a Speed Dependent Tool Pressure Both parameters are specified in the Configure Tools or Opened Job Layer structure Constant Tool Pressure In the dialog specify the T...

Page 151: ...Speed Dependent Tool Pressure In the dialog specify Ramp and a Ramp Value The Ramp Value is entered as a value The upper curve illustrates the speed of the machine when executing a line Curve A illustrates the Knife Pressure if the Speed Dependent Pressure is set to 0 the pressure is constant from start to stop TheKnife Pressure level is as specified by the Knife Pressure parameter see previous cha...

Page 152: ...clamp C as indicated to lock the Knife Shaft 2 Turn the screw S to adjust the Cutting Depth When seen from the Knife Blade side a clockwise adjustment will increase the Cutting Depth 12 18 RotaCut RotaCut is a special tool for cutting light materials as thin fabric Maximum Cutting Depth is 2 mm 0 07 inch Note Due to the characteristics of this knife tool some restrictions apply to the use of it 15...

Page 153: ...p angles RotaCut is prepared for Decagonal Knife Blades ø25 mm 1 inch How to replace the Knife Blade Warning Sharp tool 1 Use the spanner and the hexagonal screw driver to remove the Knife Blade fixing nut 2 Carefully remove the old Knife Blade and insert the new one Ensure the Knife Blade is properly seated Mount the nut and fix it properly 153 ...

Page 154: ... movement is smooth Tool Adjustment RotaCut is adjusted in the same way as the other C tools regarding rotation angle and offset Tool Height is manually adjusted Tool Height for RotaCut is manually adjusted using the tool height adjustment wizard available from the Tool Configuration dialog Follow the instructions in the dialog Be careful though not to adjust the cutting depth too deep into the Cut...

Page 155: ...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 The supplied milling bit is heavily unbalanced and should ...

Page 156: ... area Preferably the milling underlay or your selected substrate It is important that the piece of tape fits within the hole in the measuring foot with good margins 3 Insert the Braille Tool in the MultiCUT tool head 4 Open up the Tool Adjustment dialog 5 Select Braille Tool and press Adjust Active Tool 6 Select Tool Offset Adjustment and press Next 7 Jog the tool head to the position of the tape s...

Page 157: ...Velocity Z is material dependent and may require experimentation The value shown in the illustration is suitable for and has been tested with 3mm Dibond Z axis depth Z axis depth is determined by the material thickness and hole depth It can be calculated as Z axis depth hole depth material thickness According to the Raster Braille manual the hole depth should be 1 07mm 0 042 You may find that the h...

Page 158: ...by letter translation of texts If you wish to create Grade 1 braille signage you can use any available braille font These fonts may be freely available on the internet Grade 2 braille introduces abbreviations and contractions for a large number of commonly used words This is the recommended preferred method of creating braille texts For Grade 2 braille you will need dedicated translation software ...

Page 159: ...or cutting corrugated materials Maximum material thickness 7 mm 0 28 in Maximum knife edge height 6 5 mm 0 26 in requires minimum 0 5 mm 0 02 in crush During processing the corrugated material is partly crushed by the foot The result is You can run at high speed The risk for material tear is significantly reduced Foot pressure adjustment 159 ...

Page 160: ...sure 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 this you can find and save settings that are optimal for each type of material Note When adjusting the knife tip exposure do not adjust the knife tip too far into the foot The limit is when the knife ti...

Page 161: ...nt For this tool complete the following adjustments Parameter Description Lag Setting The knife lag depends upon the blade shape Normal value is 0 mm Tool Height The tool tip should touch the material surface 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...

Page 162: ... for use in combination with HPMU Braille Tool how to add spheres 1 Keep the tool in upright position during this process 2 Remove the cap and the plunger 3 Pour spheres into the tool 4 Insert the plunger and the cap Shake the tool lightly 5 Push the dispensing mechanism up 6 One sphere should be pushed out from the tool 162 ...

Page 163: ... 000rpm Braille Tool setup In order to create high quality consistent braille patterns you should perform Tool Height and Tool Offset calibrations Before adjusting offset you should set the tool height of the Braille Tool This can be done manually or automatically using X Pad Note It is crucial that the Tool Height is correctly set before running this tool The nominal value is Tool Height Material...

Page 164: ...the material thickness and dispense a sphere onto the tape piece If the Laser Spot is offset from the sphere jog the tool head until the Laser Spot is placed exactly on top of the sphere 10 Click Finish and close the remaining tool adjustment dialogs Configure Tool Menu Bar Advanced Configure Tools Braille Tool should be defined with the following parameters enabled Velocity Z max speed Z axis Depth ...

Page 165: ... sit too low or 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...

Page 166: ...shing 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 with the HPMU spindle as well as Brail...

Page 167: ...ked in position To remove a Tool press the Release Button Pen Drill Motor Connector To release grab the housing and lift straight up To insert move connector carefully down and turn it until it fits Then just push the connector down until it is locked in position 167 ...

Page 168: ... chuck Use the wrench to fix the bit in the chuck No additional adjustments are necessary as the tool height is measured automatically Tool Adjustment For this Tool complete the following adjustments Adjustment Description Tool Height Measured automatically possible to add an Offset Value Tool Offset Adjust offset relative to Laser Pointer For more information about how to run the Adjustment Wizard...

Page 169: ... spring and Pressure Adjustment Knob C pen tool Adjust Tool Pressure using the screw s Lock the adjustment screw using the locking knob k Tool Adjustment For this tool complete the following adjustments Adjustment Description Tool Height Measured automatically possible to add an offset value Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to laser pointer For m...

Page 170: ...n 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 sec time out Pressing any button on ...

Page 171: ...ularities Clean The Table Surface should be kept clean at all times For cleaning use iso propyl alcohol or white spirit The room should be cleaned regularly Keep the cables free from grease floor vax etc Use a Vacuum Cleaner to keep the inside of the Conveyor belt clean Inspect and clean if necessary the inside of the milling suction house 13 3 Weekly Maintenance Guide ways and Bearings The guide w...

Page 172: ...ring the first few seconds of operation 3 Remove and clean the bowl if the automatic draining action does not operate or if it appears to be an excessive amount of dust in the bowl Warning If the automatic draining action fails water can enter the Tool Assembly resulting in severe damage 13 4 Monthly Maintenance Warning The Main Power should be switched off before any maintenance is carried out Mon...

Page 173: ... gear wheel it is important that the grease is distributed around the wheel In one spot apply just a small amount of grease one push Move the traverse or carriage a little in order to turn the gear wheel Repeat this procedure 5 times on each wheel X1 axis gear X2 axis gear 173 ...

Page 174: ...13 Kongsberg XP Y axis gear Racks The racks in X1 X2 and Y should be re greased 174 ...

Page 175: ...bove Y above Procedure Use the soft brush to apply grease to the racks No covers have to be removed to complete this procedure Apply small dots of grease every 25 cm 10 inch along the entire length of the rack on X1 and X2 side 175 ...

Page 176: ... close to the middle short line as shown If this is not the case the conveyor should be checked by a trained technician On lower rear roller there are pneumatic mechanisms for auto correction of the conveyor position These will slightly move the roller in and out to corrigate the belt position Observe the system in regular production If this movement is frequent i e more often than once per five fu...

Page 177: ...etain the hold down e ciency Use a steel pin 0 5 0 6 mm While the vacuum system switched on free the vacuum holes by pushing the obstructions down into the table 13 5 Maintenance External Equipment All external equipment as PC Vacuum pump and compressor should be maintained according to the User Manual for the actual equipment 13 6 Maintenance Take Up Unit 13 6 1 General There is no specific need f...

Page 178: ...out 13 6 2 Spare Parts Spare parts available Part no Description 42468512 TAKEUP_GASSPRING 42468520 TAKEUP_GASSPRING GUIDING ROLLER 42468538 TAKEUP_ TOP GUIDING ROLLER 42468546 TAKEUP_POTENTIOMETER DANCERROLL 42468553 TAKEUP_RUBBERCORD Ø11MM 42468561 TAKEUP_ COVER BEARING BLOCK 42468579 TAKEUP_ SWITCH EMERGENCY STOP 178 ...

Page 179: ...lug from the wall socket Note Some equipment described might be optional 14 1 MPU 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 base cover in front of MPU 2 Remove one fuse and check with ohm meter If blown replace with a new identical fuse 179 ...

Page 180: ...nd turn main power on Fuse Details All fuses are 1 1 4 x 1 4 in 6 3 x 32 mm Fuse location 115V 230V Line fuses F1 and F2 T 15A 250V T 6 25A 250V 200V Servo power fuse F200 T 15A 250V T 15A 250V 48V Servo power fuse F48 T 8A 250V T 8A 250V 24V fuse F4 T 6 25A 250V T 6 25A 250V 14 2 X1 X1 Amplifier Location 180 ...

Page 181: ...dure 1 Remove X1 cover 2 Remove cover from AC amplifier unit 3 Check fuses F2 F5 with ohm meter If blown replace with a new identical fuse 4 Replace covers 5 Insert main power cable into the wall socket and turn main power ON Fuse Details T 10A 250V 5 X 20 mm 14 3 X2 181 ...

Page 182: ... Location Procedure 1 Remove X2 cover 2 Remove cover from AC amplifier unit 3 Check fuses F2 F5 with ohm meter If blown replace with a new identical fuse 4 Replace covers 5 Insert main power cable into the wall socket and turn main power ON 182 ...

Page 183: ...14 Kongsberg XP Fuse Details T 10A 250V 5 X 20 mm 14 4 Y Y Amplifier Location Fuse Location 1 Y motor with encoder 2 TCU 3 AC amplifier for Y 4 Z1 motor 5 Z2 motor 183 ...

Page 184: ...m AC amplifier unit 3 Check fuses F2 F5 with ohm meter If blown replace with a new identical fuse 4 Replace covers 5 Insert main power cable into the wall socket and turn main power ON Fuse Details T 10A 250V 5 X 20 mm 14 5 P1 P2 fuses P1 P2 Amplifier Location 184 ...

Page 185: ... motor 5 P2 motor Procedure 1 Remove Y cover 2 On the TCU unit check fuses Fz1 and Fz2 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 4A 250V 1 1 4 x 1 4 in 6 3 x 32 mm 185 ...

Page 186: ... lift straight up 4 Check with ohm meter If blown replace with a new identical fuse 5 Insert main power cable into the wall socket and turn main power ON 6 For information about fuse sizes see table below Fuse Details Tool Head Function Fuse Fuse Size Fuse Type Drill Tool Drill Fhr 2 T 2A 125V NANO 42441618 Hiforce Knife Tool Tool Rotation Fhr 2 T 2A 125V NANO 42441618 HF VibraCut Knife Tool Tool ...

Page 187: ...2441618 VariCut Knife Tool Knife Depth Fu d 0 5 T 0 5A 125V NANO 42441600 VibraCut Knife Tool Tool Rotation Fhr 2 T 2A 125V NANO 42441618 VibraCut Knife Tool Vibration Fu d 2 T 2A 125V NANO 42441618 HDU XP Tool Rotation Fhr 4 T 4A 125V NANO 42444828 Dual HDU Tool Rotation Fhr 4 T 4A 125V Nano Dual HDU Tool Up down Fu d 0 5 T 0 5A 125V Nano VariAngle unit Tool rotation Fhr 4 T 4A 125V NANO 42444828...

Page 188: ...pare fuse 2 Fuse in action Fuse when mains 115V T 2A 250V 5x20 mm 42424150 Fuse when mains 230V T 1A 250V 5x20 mm 42468058 14 8 Heater for Chiller Fuse Heater Fuse Location The Fuse is available inside the connector cover Fuse details F 4A 250V T 5x20mm Slow Blow 42448944 14 9 Chiller 2016 Chiller 2020 Fuse replacement 188 ...

Page 189: ...m 42468066 F3 T 500 mA 250V 5 X 20 mm 42468074 Fuses when 230 V F1 T 12A 250V 5 X 20 mm 42468082 F2 T 12A 250V 5 X 20 mm 42468082 F3 T 500 mA 250V 5 X 20 mm 42468074 14 10 Sound Insulating Box Circuit Breaker for fan A separate circuit breaker for 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...

Page 190: ... for the problem Set the ON OFF switch A to ON 14 11 TakeUp Unit Fuse replacement The fuses are mounted on the main electrical mounting plate behind the sheet metal cover on the right side of the machine Fuse F1 T10 A 250V 5x20mm 42448985 The same fuse size is used regardless 115V 230V 190 ...

Page 191: ...electrical mounting plate behind the sheet metal cover on the right side of the machine The same fuse sizes are used for 115 V as well as 230 V Spare fuses are found in each fuse holder as well as in the accessory kit Fuse 10F1 T10 A 250 V 5x20 mm 42448985 Fuse 10F3 T3 15 A 250 V 5x20 mm 42476168 Fuse 15F1 T100 mA 250 V 5x20 mm 42476184 Fuse 15F2 T5 A 250 V 5x20 mm 42448951 191 ...

Page 192: ...14 Kongsberg XP 192 ...

Page 193: ...rake Position Locker D Roller Brake E Brake Tension adjustment Turn clockwise to increase tension To adapt to different roll sizes three Roll Holder Positions are prepared To move the roller bracket remove pin A and release locker C To disengage the Roller Brake release the Brake Position Locker C and tilt the bracket 193 ...

Page 194: ...16 Collector Basket The unit is placed in the unload end of the conveyor belt front of table The unit is prepared for rigid pieces up till 200x200 mm 8x8 in or flexible materials Maximum load weight is 30 kg 65 lbs 194 ...

Page 195: ...this manual carefully before starting the machine Familiarize yourself thoroughly with the functioning of the machine Strictly observe the directions given Liability The data published in this manual are based on the latest information available They are subject to future modification We reserve the right to change the construction and or design of our product without being obliged to adapt earlier...

Page 196: ...fely We have made everly effort to inform you as correctly and completely as possible on any dangers associated with the operation of the machine You must ensure and are responsible for compliance with these behavioural guidelines The buyer user is obliged to familiarize operating cleaning and maintenance personnel with these instructions 17 2 Machine Description The TakeUp Unit is a machine speci...

Page 197: ... machine This autogrip shaft has a variable winding speed depending on the height of the dancer roller Machine Identification The TakeUp Unit has an identification label a typical label is shown in the picture The identification label is positioned on the left side of the machine where the power cable is entering the machine 17 3 Safety General The TakeUp Unit has safety equipment to promote safe mac...

Page 198: ...he machine have understood the basic rules on workplace safety and accident prevention The owner will make sure that the personnel is trained in the handling of the machine and have been familiarized with the operating and safety instructions contained within this manual The safety awareness of personnel shall be reviewed at regular intervals Obligations of the Personnel All individuals working wi...

Page 199: ...sures The user manual must be kept with the machine In addition to the operating instruction the local accident prevention regulations and environmental regulations should be available All safety instructions and warning pictograms must remain in legible condition Security Measures for Normal Operation Only operate the machine if all safety features are fully functional Before start up of the mach...

Page 200: ...ol positions The TakeUp Unit is normally operated from the right side of the machine Controls At the left side of the frame are the operating switches These switches allow the operator to control the power on or off the turning direction the winding speed and the possibility to jog the machine The different controls are shown in picture 200 ...

Page 201: ...tion The winding direction button controls the winding direction of the TakeUp Unit C Winding speed The windig speed potentiometer controls the winding speed D Spare E Power button The power button switches the machine on or off F Control lamp The control lamps indicates if the machine is turned on or off 17 6 Applying Winding Material Applying winding material to the Autogrip shaft 201 ...

Page 202: ...it with tape in a straight line onto the coil See picture for the typical loop of the winding media Avoid angular tension in the media the media will start telescoping during the winding Note TakeUp Unit should be started only when material is in place Infeed loop Aligning the media on the Autogrip shaft 17 7 Start the TakeUp Unit The TakeUp Unit is activated for processing when The power button i...

Page 203: ...ll central on the autogrip shaft which uses rubber blocking cords to grip with Rotate the core media roll to engage it with the autogrip shaft Note If a core media roll of the same size is often used install a roll clamp at one side of the shaft to enable easy replacement Autogrip shaft installation The shaft is hung in a special T slot on one side of the machine and a suspension point on the othe...

Page 204: ...e exchanged Before cutting the media the TakeUp Unit has to be always switched off The tip has to be stuck to the roll to prevent unwinding during transportation The TakeUp Unit is provided with a jog button to get an easy exchange of the rollers This makes is possible to rotate the roller contrary by hand to get the T slot in position to exchange the media roll Attention When removing the Autogri...

Page 205: ...ler will move to its lowest position when a roll of material is completed The TakeUp Unit will shut off automatically when the dancer is longer then 4 seconds in the bottom position The full roller can now be replaced by a new empty core The TakeUp Unit can be restarted by switching the winding direction to 0 and then back to a winding direction The TakeUp Unit will now start winding till the danc...

Page 206: ...g Edge Control Centering button E 5 Make sure the dancer is in upper loading position 6 Load material in loop a Unwind enough material to feed the loop using Manual Jog D b Push the material under the dancer bar and on to the table 7 Lower the feeder paws bar with foot pedal 8 Unlock the dancer by pulling and turn the looking bolt 9 Manually lower the dancer and check feeding direction Using Manua...

Page 207: ...19 Kongsberg XP 19 MRF Weight list For commonly used materials print out and fill in this list Material Number Material Number 207 ...

Page 208: ... 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 1 208 ...

Page 209: ...iner 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 209 ...

Page 210: ...rs and maintenance manual 20 2 Vacuum Cleaner High capacity TB ESKO 20 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 210 ...

Page 211: ...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 211 ...

Page 212: ...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 212 ...

Page 213: ... 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 213 ...

Page 214: ...20 Kongsberg XP 5 Lift and turn the container to release it from the fixture 6 Empty the container 214 ...

Page 215: ...21 Kongsberg XP 21 Install Software For information about software installation see the Installation Manual for the actual machine Available on the Documentation DVD 215 ...

Page 216: ...nsmitters 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 be the...

Page 217: ...le 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 2 or 3 tools are working at the same time Check your compressed air make sure you have 7 bar Check compressed air connection at the he...

Page 218: ...erg XP 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 the emergency button 218 ...

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