Esko Kongsberg XN IPC 2.0 User Manual Download

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Kongsberg XN / iPC 2.0

User Manual

01 - 2017 | XN

Summary of Contents for Kongsberg XN IPC 2.0

Page 1: ...Kongsberg XN iPC 2 0 User Manual 01 2017 XN ...

Page 2: ...Definition of use 14 5 5 Danger Zones 14 5 5 1 Danger Zones 15 5 5 2 Moving Parts Laser Radiation and High Voltage 15 5 5 3 Loose Clothing 16 5 5 4 Noise Level 16 5 5 5 Ejection of Parts 16 5 5 6 i Camera strobing light 17 5 6 Warning Sign Explanation 17 5 7 Safety devices 19 5 7 1 Overview 19 5 7 2 Emergency Stop Button 19 5 7 3 Warning Lamp on top of Y Carriage 20 5 7 4 DynaGuard Safety System 2...

Page 3: ... 8 10 Make a Pen Plot 36 8 11 Work with X Pad 36 9 How To Procedures Advanced 40 9 1 Cutting Thick Materials 40 9 2 Hard Board Production 40 9 3 Multi Pass Milling 41 9 4 Jobs including Reverse Operation 41 9 5 Work with different Reference Point Settings 42 9 6 MultiZone Production 42 9 6 1 MultiZone Workflow 44 10 System Setup 46 10 1 Introduction 46 10 2 Adjust X1 to X2 Angle 47 10 3 Register T...

Page 4: ...set 62 11 9 Maintain Tool List More 63 12 Tooling System 65 12 1 Tool handling and care 65 12 2 Tool Inserts with built in motor 65 12 3 Tool Heads available overview 66 12 4 Tool Head mount dismount 67 12 5 FlexiHead 67 12 6 PowerHead 69 12 6 1 ø150 mm Crease Wheel 70 12 6 2 Crease Adapter ø26 mm 70 12 6 3 Perforation Wheel ø60 mm 71 12 6 4 HD Knife Tool 73 12 6 5 V notch Knife 73 12 7 FoamHead 7...

Page 5: ...2 Tool Depth and X Pad 114 12 13 3 Limitations 114 13 Tool inserts 115 13 1 Ball Point Pen 115 13 2 Bevel Knife 116 13 3 Bevel Knife U20 117 13 4 Braille Tool 117 13 5 CorruSpeed Knife 122 13 5 1 Tool adjustment 123 13 6 Crease Tool 124 13 6 1 Tool adjustment 124 13 7 Crease Tool 60 mm 125 13 7 1 Tool adjustment 125 13 8 Drill tools 126 13 8 1 Flexi Drill Tool 126 13 8 2 Reboard Drill Tool 127 13 ...

Page 6: ...147 15 Fuse replacement 148 15 1 MPU fuses 148 15 2 X1 fuses 149 15 3 X2 fuses 149 15 4 Y Z fuses 150 15 5 Tool Rotation Reciprocating knife fuses 151 15 6 Chiller fuse 151 15 7 Heater for Chiller Fuse 153 15 8 Chiller2016 Fuse replacement 153 16 Roll Feeder 154 17 Collector Basket 155 18 Vacuum Cleaner 156 18 1 Vacuum Cleaner Zefiro 156 18 1 1 How to use 156 18 2 Vacuum Cleaner High capacity TB E...

Page 7: ...ed 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 change without notice Revisions may be issued from time to time to advise of such changes and or additions No part of this system may be reproduce...

Page 8: ...zed 18 10 2016 jhbe CorruSpeed information updated 24 10 2016 jhbe MultiCUT HP new chiller and information about old chiller added 15 11 2016 jhbe MultiZone Production recommended workflow emphasized 18 11 2016 jhbe V notch description improved 28 11 2016 jhbe Measuring foot soft springs introduced 29 11 2016 jhbe Psaligraphy knife tool information added 14 12 2016 jhbe MultiCUT HP chapters update...

Page 9: ...nsole iPC Thus actual GUI functions will be referenced in this manual but the complete and comprehensive description is available in the User Manual 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 equipment...

Page 10: ...ine Prepare for 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 MultiZone Production how to Tool Configuration and Adjustment General information about the tooling and adjustment of tools Tooling System Tool desc...

Page 11: ... 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 indicates that the function is license dependant 4 3 Pictur...

Page 12: ...4 Kongsberg XN iPC 2 0 12 4 4 Local Languages This manual is available in a wide range of local languages Screen pictures and illustrations remains in English language ...

Page 13: ...e topics 5 2 Responsibilities 5 2 1 The Manufacturer The Manufacturer is responsible for delivering the system according to Safety Regulation standards 5 2 2 The Customer The Customer is responsible for Ensuring that the system is used for it s Intended Use only Allowing that only authorized and trained personnel operate the system Preventive maintenance as described in the Maintenance chapter Tha...

Page 14: ...oduction Console In this 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 Utilizing accessories other than those...

Page 15: ... 2 0 15 5 5 1 Danger Zones The area around the moving parts is considered to be a Danger Zone The Danger Zone is identified by the means of a yellow black floor marking 5 5 2 Moving Parts Laser Radiation and High Voltage ...

Page 16: ...t Use ties Use loose necklaces Use scarfs 5 5 4 Noise Level Hearing Protection should be used by any personnel exposed to the noise from the machine 5 5 5 Ejection of Parts Potential risk when running MultiCUT Personnel hit by breaking milling bit or small pieces of processed material ...

Page 17: ...ns 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 the camera configuration menu At that rate seizures are not known to happen 5 6 Warning Sign Explanation Knife Blades are extremely sharp This symbol is used in this documentation to indicate operations with Knife Blades and Milling Bits Hand Squeeze Poten...

Page 18: ...on is compulsory Eye Protection The Eye Protection symbol indicates areas where the use of eye protection is compulsory Moving Parts Potential areas with a risk of being hit by Moving Parts are marked with the Moving Parts sign These areas are Both traverse ends Y carriage Tool head s The Main Power Unit MPU contains Mains Voltage and may be opened by Authorized Personnel only The MPU is marked wi...

Page 19: ... Power Switch 2 Emergency Stop Button 3 Warning Lamp Status Lamp 4 Photo cell supervision Dynaguard 5 Traverse Stop Switches Dynaguard 5 7 2 Emergency Stop Button Switch positions OUT Emergency Stop is switched OFF IN Emergency Stop is switched ON Mains Power to the machine is switched off ...

Page 20: ...ety System to continue operation 5 7 4 DynaGuard Safety System The DynaGuard Safety System consists of two light beams in front of the traverse and one behind In addition there is a 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 are broken The stop mechanism is activated for instance when a person is stan...

Page 21: ...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 level will vary with the type of operation and tooling but a typical average level is 78 5 83 5 dBA and a maximum level of 98 5 dBA 5 9 Procedures in case of malfunctions Trouble shooting and repair shall be executed by Authorized Personnel only C...

Page 22: ...ath 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 while the machine is working Rear side of traverse ...

Page 23: ...movement when hit When the Feeder Paws are mounted the distance between beam c and the mechanics is reduced Actions Stay 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 ...

Page 24: ...ation and Conveyor belt 1 Table Top 7 Front cover including Operator Panel 2 Traverse 8 Main Power on off switch 3 Y carriage 9 Traverse Safety Stop switches DynaGuard 4 Tools 10 Operator Station Operator Panel 5 Main Power Unit MPU Air Pressure Regulator 11 Conveyor belt 6 Emergency Stop button 12 Gallows for MultiCUT ...

Page 25: ...X1 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 ...

Page 26: ...Operation Pause Safety System Reset Press this button to Pause Operation and Reset Safety System Vacuum On Off Press this button to switch Vacuum On Off Provides material hold down Set Panel 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 ...

Page 27: ...ction see Option System setup Incremental Jog Press this button to select Incremental jog mode Press the button a second time to disable Incremental jog mode Press the two arrows to move the tool head a large step Press the single arrow to move the tool head a small step The size of the incremental movement can be changed from Machine Configuration Setup Tool Down Press the Tool Down button to man...

Page 28: ...low to a suitable level for the actual material Use this function to manually enable Blow Back 6 5 Pressurized 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 Tube R Pressure Regulator Valve P Pressure Gauge W Water Trap T Air Tub...

Page 29: ... find Air Pressure Regulator 6 6 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 HWT800 Hardware test program see separate HWT800 User Manual ...

Page 30: ...tions 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 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 Sys...

Page 31: ...vo 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 switched on again 3 Front End PC To switch off the PC use the Operating System shutdown procedure 7 4 Continue after Safety Break If the Safety System is activated all movements on the table are stopped and the Warnin...

Page 32: ... XN iPC 2 0 32 2 Reset the Safety System by pressing the Pause pushbutton 3 The Warning Lamp on top of the Y carriage should be on without flashing Observe that Servo Power is switched on 4 Press Start to continue ...

Page 33: ...tarting 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 Cr...

Page 34: ...arking 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 From the Vacuum Zone setup dialog configure a suitable vacuum area for the job Select Vacuum Z...

Page 35: ...ay 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 Milling Production Be...

Page 36: ...nsure the Ballpoint Pen is clean and ready to use 8 11 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 Automatic tool height m...

Page 37: ... 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 Pause button light...

Page 38: ...egative 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 t...

Page 39: ...8 Kongsberg XN iPC 2 0 39 All Measuring Pad operations are cancelled by Press Close in the active dialog Press Pause on Operators Panel ...

Page 40: ... for Knife 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 t...

Page 41: ...n the path Multi Pass Milling is beneficial if you want to mill through a material where the thickness is bigger than the router bit diameter 9 4 Jobs including Reverse Operation Step 1 the sheet is aligned towards the Right Ruler Reverse Operations are completed Step 2 the sheet is aligned towards the Left Ruler The rest of the job is completed ...

Page 42: ...is equipped with left and right rulers Note Reverse Operation is not available on machines with conveyor belt Reverse Operation in combination with Step and Repeat For each copy defined by Step and Repeat you have to move the sheet first against the Right Ruler then against the Left Ruler 9 5 Work with different Reference Point Settings Select the Reference Point to use from Opened Job Production ...

Page 43: ...ion is available In this chapter more machine specific issues are described MZP Panel Each work zone is equipped with a panel that makes it possible to run the complete MultiZone Production sequence from the table 1 Ready Lamp 2 Ready Button 3 Vacuum on Button 4 Vacuum Lamp Vacuum Zones Vacuum Section Configuration on page 53 ...

Page 44: ...ilable for MultiZone Production Limitations The last section of a multizone table is somewhat smaller than the first one s As a consequence the work area available for MultiZone Production is determined by the size of the last section W XN24 W XN44 W XN46 W XN48 9 6 1 MultiZone Workflow ...

Page 45: ...erse will move into the 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 ...

Page 46: ...ttings 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 tab...

Page 47: ...t 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 Table in order to measure the table size Typical use is after maintenanc...

Page 48: ...rocedure if mechanical maintenance has been carried out on the table or traverse Correct registration of the Right Ruler is required when Reverse Operations are carried 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 m...

Page 49: ...Mat has been replaced Procedure 1 If the table is equipped with a Conveyor Belt move the belt junction away from the table surface 2 Execute the Map Table Top function 3 Follow the instructions given by the wizard 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 selecte...

Page 50: ...he Main Reference Point has to be correctly positioned 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 o...

Page 51: ...e 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 same time the direction of the X axis is reversed 10 8 Table Speed Menu Bar Advanced Configur...

Page 52: ... acceleration for this particular Job 10 10 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...

Page 53: ...calculation 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 th...

Page 54: ...ne time job as long as the Vacuum Section Solution on the machine remains un changed The setup should correspond to the actual hardware The selected setup will determine which Vacuum Section Configuration that will be available in the User Interface Machine Zone Configuration Vacuum Configuration XN20 14 XN22 14 XN24 12 XN40 14 XN44 12 ...

Page 55: ...Machine Configuration HW Configuration Router Setup From the Router Setup dialog maintain the following parameters Specify Router If a Router is mounded spedify Router Type If no Router is mounted select None COM port The physical COM port used for communication with the Router Control Unit is specified Note The Router Control Unit needs to be connected to a genuine COM port If connected to a USB ...

Page 56: ...In some occasions the sheet unloaded from the cutting table can trigger the photo cell safety system To avoid this the sheet feed movement is divided into two steps 10 14 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 15 Board Size Not implemented yet ...

Page 57: ...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 See the description of each Tool Type for more specific information ...

Page 58: ...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 Active Tool button to ente...

Page 59: ... the back 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 ...

Page 60: ...o 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 Select Manual Adjustment of...

Page 61: ...y 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 mounted Manual Adjustment 1 Place an appropriate test material ...

Page 62: ...es 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 the new settings Note All tools ...

Page 63: ...tep by 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 Identifica...

Page 64: ...11 Kongsberg XN iPC 2 0 64 Add new Tools Add tools that fails during Automatic Tool Detection The Tool is added to the Tool List ...

Page 65: ... 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 the FlexiDri...

Page 66: ...croCut RotaCut Knife Drill Tool Pen Foam Knife PowerHead PowerHead is a special purpose Tool Head which can be equipped as follows Two general tool positions prepared for the standard FlexiHead tools PowerHead ø150 mm Creasing Tool for heavy duty creasing with high pressure and suitable wheel geometry Adapters for smaller Crease wheels ø26 mm ø60 mm V notch Knife Prepare a V cut in triple wall mat...

Page 67: ... 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 12 4 Tool Head mount dismount Be careful not to apply too much force when fixing the signal cables 12 5 FlexiHead ...

Page 68: ...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 Replace a Tool Insert Observe the alignment pins Press the locking knob down Tool Adjustments FlexiHead Tool Height Correct tool height relative to table top Lag Setting ...

Page 69: ...PowerHead Tool Head Description 1 Tool position 1 FlexiHead tool insert 2 Tool position 2 FlexiHead tool insert 3 Tool position 3 4 Laser Pointer 5 Measuring foot material hold down foot 6 Electrical connection reciprocating motor Tool Adjustments PowerHead Tool Height Correct tool height relative to table top Lag Setting The lag value depends upon the blade adapter Nominal value is 0 mm ...

Page 70: ...se Wheel This Crease Wheel has the equivalent of 50kg 110lb of down pressure The additional pressure combined with the large frontal area of the big wheel enables excellent crease quality in heavy duty corrugated board and even permits creasing board with high recycle content without breaking the liner A broad range of wheels with different shapes is available How to mount dismount the Crease Whee...

Page 71: ...he Heavy Duty crease tool position The tool is adjusted and operates as an ordinary crease tool 12 6 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 ...

Page 72: ...ete the following adjustments Adjustment Description Tool Height Measured automatically 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 ...

Page 73: ...Tool Configuration chapter 12 6 4 HD Knife Tool The HD Knife Tool is inserted in the HD 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 ...

Page 74: ...e V notch Knife A correctly to fit the alignment pin B Both latch pins are used for the V notch Knife How to replace a Knife Blade This picture shows how the Knife Blade is aligned using two guide pins beneath the blade clamping 1 Loosen the two screws 2 of the Knife Blade clamping 2 Carefully remove the blade 1 ...

Page 75: ...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 material should be carried out Tool Height Correct tool height relative to table top Lag Setting Nominal value is 0 7 mm Tool Rotation Adjust tool angle tangential to mov...

Page 76: ...th of the V notch cut From the dialog modify the default width V notch 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 V notch Knife Tool Modes of Operation Note V notch Knife Adapters are available for different knife angles In this chapter a 45 o knife angle is discussed The programming and operation ...

Page 77: ... of the cut Note This function is working along Y only Flute direction must be along Y The numbers indicates sequence of operation 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 Geometry When the knife angle is 45 o and you cut...

Page 78: ...lly the width of the cut has to be increased by dW 2 x bottom liner thickness dW limitations 20 mm dW 20 mm 0 8 in dW 0 8 in Decide if Triple Cut Function is needed This illustration shows how the parameter dW is used to ensure a nice folding result Adjustment sign and cut direction 12 7 FoamHead Tool Head Description 1 Height sensor 2 Knife adapter 3 Material hold down wheels Operator protection ...

Page 79: ...ustment wizards see Tool Configuration Partial through cut Partial through cut is specified as an absolute value or a percentage value in the Job Setup dialogue Please note that the value is specified from the top of the material and down Cutting quality To obtain best quality when cutting details as small circles we recommend Reduce the cutting speed from Job Setup Cut in two or three passes each...

Page 80: ... Tool the Disable Material Thickness Measurement function is available Use this function if Your foam material is too soft for the measuring system 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 underlay During Tool Up movements the knife is lifted to its top posi...

Page 81: ...hich 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 Power rating max 3 kW Cooling system Liquid cooling Shank size max 8 mm RPM max 60000 Tool change Pneumatic Vibration sensor board No ...

Page 82: ...described in detail in Chuck Change and Cleaning on page 96 This chapter is included just to remind you how important it is to use the Chuck Changing Tool available and a dummy bit to ensure correct mounting From left Chuck tool dummy bit with right diameter for the chuck and chuck Chuck change assembly Ready to be inserted into the spindle 12 8 2 Tool Head description ...

Page 83: ... motor 7 Electrical connection reciprocating motor 8 Suction hose 9 Cooling water connectors 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 3 Warning Lamp for spindle ...

Page 84: ...Chuck 5 Air Clean Button to help remove contamination 6 Locking Screw for the suction house Use this screw to lock the suction house in a certain height 1 Router Bit 2 Chuck MultiCUT HP is equipped with one 6 mm chuck on delivery 3 Spindle Water tube connections Connect water tubes Push the tube connectors into the receptors Sequence is not important Release water tubes Pull down the release locke...

Page 85: ...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 Suction house adjustable height On MultiCUT HP you can lock the suction house in any height still it is allowed to move upwards This function is useful in order to 1 Adapt to different material thicknesses 2 Allow false air input in order to re...

Page 86: ... mm bits are preferable in materials up to 20 25 mm thickness 12 8 3 Safety Issues Unattended Operation Depending upon the material processed milling introduce 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 This might cause damage Ensure the filter inside the Vacuum Clean...

Page 87: ...ltiCUT MultiCUT HP Hearing protectors The noise generated by milling varies with the material being processed and running parameters Use hearing protectors when necessary Spindle speed Never use speeds higher than recommended by the bit supplier Special care should be taken when using bits with cutting diameter larger than shank diameter Router bits Router bits are very sharp handle with care Neve...

Page 88: ...good working conditions for the Spindle Motor Too high Spindle Power consumption indicates critical conditions for the motor and immediate actions should be taken 1 Use correct and sharp 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 f...

Page 89: ...he spindle is running This will destroy the spindle Air Pressure and Quality Never run IBAG spindle with Pressurized Air disconnected This may destroy the spindle Keep this in mind also for test purposes Use clean air Never run IBAG spindle 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 ...

Page 90: ...ultiCUT 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 increasin...

Page 91: ...ner in time 1 Do not leave the machine running if the Vacuum Cleaner can be over filled This might cause damage 2 Be aware the risk of suction tube clogging 12 8 5 Routing Advice Milling bits For thin materials use bits with short cutting length ...

Page 92: ...er 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 Router Bit Edges are brittle Never let bits touch each other or other h...

Page 93: ...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 determine the final Feed Rate for an application A large drop in RPM or a high Watt value in the display indicate too high Feed Rate Large diameter bits require more power than small diameter bits Worn bits increase the Power Consumption Number of passes in thick...

Page 94: ...ssary to reduce the acceleration in order to achieve an optimal Cutting Quality when combining a heavy tool head with high quality cutting tools 12 8 6 Cleaner Device Cleaning the suction house is simple using a Cleaner Device which is available as an option 12 8 7 Bits and Bit Change How to insert replace a router bit 1 Ensure the Spindle is not running the lamp is dark Mind the sharp bit and mov...

Page 95: ...e Chuck Open Close lever down to open the Chuck Put the bit in a proper storage container Insert a new Router 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 100 chapter for more information 4 Release the Lock to allow the Suction House moving down to its down position ...

Page 96: ...or the Pressurized Air source If the bit is still stuck see the Chuck Change and Cleaning on page 96 section about how to unscrew the chuck 12 8 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 imp...

Page 97: ...n 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 ...

Page 98: ...ether with a dummy bit to unscrew the chuck This procedure might be necessary if a bit is stuck 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 ...

Page 99: ...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 11 Chuck Maintenance Kits are available in the Esko Store on www esko com ...

Page 100: ...n New chucks are available from Esko store 12 8 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 For proper clamping keep distance e 20 mm 0 8 inch as a minimum To achieve material through cut the distance d must be at least 18 mm 0 7 inch Balanced Bits Bits...

Page 101: ... complete relevant adjustments as described for FlexiHead For the router 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 adjustment wizards see Tool Configuration Notes regarding Tool Height adjustment When properly ad...

Page 102: ...is 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 drill bit is stopped 2 mm 0 08 inch above the cutting underlay Thus it is not possible to mill through the material in this case Tool height will follow the mapp...

Page 103: ...scellaneous Warm Up Machine Panel Toolbar Warm Up To protect the Spindle mandatory Warm Up is implemented If the Spindle has been inactive for 8 hours or more a 3 min Warm Up is required If the Spindle has been inactive for 4 weeks or more an extended sequence is required called Run In This takes 20 minutes Suction house Clean the suction house when necessary with acetone and a q tip A smooth surf...

Page 104: ...repare Layer Setup with low spindle speed zero depth and maximum feed Insert the Dummy Bit into the chuck Adjust the brush height until the brush barely touches the mat surface 12 8 15 LubriCool Introduction LubriCool mounted on MultiCUT HP A inspection window B Suction cup with nozzles LubriCool control unit ...

Page 105: ... materials where lubrication is not suitable use the ON OFF switch on the LubriCool Control Unit to switch off lubrication Inspection 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 Cleaning ...

Page 106: ... cleaning is crucial for correct operation Release locker A and remove the nozzle unit Use vacuum cleaner to clean MultiCUT HP suction house Use vacuum cleaner to clean the nozzle unit 12 9 Chiller 1 for MultiCUT HP 12 9 1 Introduction ...

Page 107: ...of range high and low 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 Te...

Page 108: ...eded Press On Off button to start the heater The letters BCS are displayed To turn unit off push and hold the button for 3 seconds Media temperature is displayed Green light on the unit is on and the specified temperature is reached Green light flashing heating elements are operating Red light on fault condition over heating cable breakdown Program selection Press and hold the Menu button for 3 se...

Page 109: ...2 10 70 7 3 10 50 7 4 10 85 4 5 10 50 4 6 10 85 5 7 10 50 5 Factory Setting Correct factory setting is Program 5 and temperature 26 oC Chiller with heater 12 10 Chiller2016 for MultiCUT HP 12 10 1 Introduction Specifications Dimensions W x D x H 480 x 580 x 430 mm 19 x 23 x 17 in Weight Empty 40 kg 88 lbs Filled with water 49 kg 108 lbs Chiller Unit ...

Page 110: ...emperature to attain proper value 19 o C 66 o F 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 range high and low Water ...

Page 111: ...ium 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 material on the table 2 Map table...

Page 112: ...t 12 12 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 afte...

Page 113: ... when the calibration procedure is carried out Ballpoint Pen Drill Tool RM Knife 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 sequence is indicated by Continuous light in the Las...

Page 114: ...wo 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 measured ...

Page 115: ... 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 following adjustments Parameter Description Tool Height The to...

Page 116: ...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 cutting depth for Bevel Knife is cut through the enti...

Page 117: ...erial 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 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 Brail...

Page 118: ...ger and the cap Shake the tool lightly 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 ...

Page 119: ... 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 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 Ac...

Page 120: ...ocity 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 hol...

Page 121: ...is a letter 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 translati...

Page 122: ...e height 6 5 mm 0 26 in requires minimum 0 5 mm 0 02 in crush Lag is nominal 0 mm 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 Material crushing depends upon two adjustments A Knife tip exposed Adjust until the distance d is 1 0 mm 0 04 in less than materi...

Page 123: ...ways point towards the cutting direction Note Be extremely careful when mounting the foot Observe the alignment pins After a blade change the tool depth should be checked again 13 5 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 ...

Page 124: ...mplete 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 information about how to r...

Page 125: ...erials avoid crease close to the Ruler 13 7 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 Tool Offs...

Page 126: ... 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 should be checked again ...

Page 127: ...epared for 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...

Page 128: ...s for Drill 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...

Page 129: ...e 2 5mm 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 ...

Page 130: ... 130 Ink 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 ...

Page 131: ...For more 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 ...

Page 132: ...es Use this 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 Pressur...

Page 133: ...adapter 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 r...

Page 134: ...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 ensure blade perpendicularity b 3 mm of the...

Page 135: ... 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 13 13 1 Tool adjustment For this tool complete the following adjustments Parameter Description Tool Height The tool tip should touch the ma...

Page 136: ...un 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 After a blade change the tool depth should be checked again 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 ...

Page 137: ...e Reciprocating Knife is available in two models Reciprocating Knife Running with 6000 RPM and amplitude 0 15 mm 0 006 inches this tool is recommended for light duty corrugated materials Lag nominal value is 0 3 mm MP HF Knife 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...

Page 138: ...rting the knife foot again Keep fingers away from knife as illustrated at left 13 15 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 Adju...

Page 139: ...fe We recommend using 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 rel...

Page 140: ... It is not 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 adjust...

Page 141: ...see Tool 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 ...

Page 142: ...achieve 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 of...

Page 143: ...XN iPC 2 0 143 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 ...

Page 144: ...eter 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 information about how to run the adjustment wizards see Tool Con...

Page 145: ...on 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 VI45 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 shoul...

Page 146: ... 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 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 ...

Page 147: ...ngs should 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 ...

Page 148: ...tion 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 socket and turn ...

Page 149: ...e 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 X2 Amplifier Location...

Page 150: ...k 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 3 Z axis motor ...

Page 151: ... x 1 4 in 6 3 x 32 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...

Page 152: ... iPC 2 0 152 Remove the on off button Remove cover 4 screws Fuse location Pull out the fuse holder Turn the fuse holder 90 deg Now you have easy access to the fuse 1 Spare fuse 2 Fuse in action Fuse T 1A 250V 5x20 mm ...

Page 153: ...016 Fuse replacement Fuses are located on the PCB inside the Chiller unit Each fuse is protected by a cover as shown upper right Lift straight up to remove Fuses when 115 V F1 T 16A 250V 5 X 20 mm 42468066 F2 T 16A 250V 5 X 20 mm 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 ...

Page 154: ...cket C Brake 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 ...

Page 155: ...2 0 155 17 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 ...

Page 156: ...g Filter 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 ...

Page 157: ...e container 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 ...

Page 158: ... Operators and maintenance manual 18 2 Vacuum Cleaner High capacity TB ESKO 18 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 ...

Page 159: ...mance 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 Use Plastic Bag in Material Container ...

Page 160: ...he 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 18 3 Compact Vacuum Cleaner 18 3 1 How to use ...

Page 161: ...anism 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 5 Lift and turn the container to release it from the fixture 6 Empty the container ...

Page 162: ...19 Kongsberg XN iPC 2 0 162 19 Install Software For information about software installation see the Installation Manual for the actual machine Available on the Documentation DVD ...

Page 163: ...all 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 t...

Page 164: ...ling spindle 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...

Page 165: ...XN iPC 2 0 165 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 ...

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