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Esko Kongsberg XL Service Manual

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See also: User Manual
We remind you that only the Esko staff, or persons having received
appropriate training, are allowed to handle, manipulate or do repairs on the system.
This copyright does not indicate that this work has been published.
All rights strictly reserved. Reproduction or issue to third parties in
any form whatever is not permitted without written authority from the publisher.
Esko reserves the right to change specifications without notice.
Document number: D3073
Status: 110905
not permitted without written authority from the publisher.
Service Guide
Kongsberg XL / i-XL tables
A Publication of: Esko-Graphics Kongsberg AS
Copyright © 1984-2013 Esko.
i-XL
Note
P.O.Box 1016, N-3601 Kongsberg, Norway
Tel: +47 32 28 99 00 Fax: +47 32 28 85 15 / 32 28 67 63
Esko-Graphics Kongsberg AS
www.esko.com

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  • Page 1 Kongsberg XL / i-XL tables Note We remind you that only the Esko staff, or persons having received appropriate training, are allowed to handle, manipulate or do repairs on the system. A Publication of: Esko-Graphics Kongsberg AS Copyright © 1984-2013 Esko.
  • Page 2 Kongsberg 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.

  • Page 3: Table Of Contents

    i-XL Service Guide Table of content INTRODUCTION ..............................5 WHAT IS I-XL COMPARED TO XL? ....................... 6 UT USER INTERFACE ............................6 HE I UT COMPUTER STAND ..........................6 HE I UT CAMERA ............................... 6 ORE VACUUM SECTIONS ............................. 7 RESSURIZED AIR SUPERVISION ..........................
  • Page 4 i-XL Service Guide 14.2 O NE VACUUM PUMP TWO VACUUM SECTIONS ....................39 14.3 T ) ........................40 WO VACUUM PUMPS OPTIONAL 14.3.1 General ..............................40 14.3.2 3 sections ..............................40 14.3.3 4 sections ..............................40 ELECTRICAL CONNECTIONS FOR CAMERA, BLOCKED SCHEMATIC ........41 ELECTRICAL SCHEMATICS .........................

  • Page 5: Introduction

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

  • Page 6: What Is I-Xl Compared To Xl

    i-XL Service Guide 2. What is i-XL compared to XL? The main differences introduced by i-XL compared to XL are: i-Cut user interface The system use i-Cut as user interface. i-Cut is a software package delivered by Mikkelsen Graphic Engineering, inc (MGE), a company sited in Lake Geneva, Wisconsin. I-Cut XL-Guide Cutting Table...

  • Page 7: More Vacuum Sections

    i-XL Service Guide Currently, the FlexiHead and MultiCut tool heads are prepared for the i-Cut camera. You will find more details in chapter 5, 6 and 7. More vacuum sections Depending upon the model type, an i-XL table will have more vacuum sections compared to standard XL.

  • Page 8: The Belt Clamps

    i-XL Service Guide The picture at left shows how to mount the belt on large tables, as i-XL24 and i-XL44. Two different air cylinder systems are used to grab the belt and move it forward. Both systems are mounted onto the traverse, as it is the traverse that actually moves the belt forward: 2.6.1 The belt clamps One clamp on each side...

  • Page 9: The Feeder Paws

    i-XL Service Guide 2.6.2 The feeder paws Four feeder paws pushes the material down towards the conveyor belt. In this way the material is fixed and kept in place during the belt movement. The position of the feeder paws along the Y-axis is adjustable.

  • Page 10: The Vinyl Roll Holder (Optional)

    i-XL Service Guide The vinyl roll holder (optional) A roll holder for vinyl rolls is available. The distance between the rolls can be changed to suit different roll sizes. Roll diameters up to ø200 mm is possible. Note: The weight of the roll has to be considered.

  • Page 11: The Main Reference Point Position

    i-XL Service Guide 3. The Main Reference point position General information about reference points Working area Main reference point All X- and Y co-ordinates in the Input program file use the selected reference point as its origin. Two modes are available: 1.

  • Page 12: Set The Main Reference Point On A Table With Rulers

    i-XL Service Guide Set the Main reference point on a table with rulers 3.3.1 If your table is running XL-Guide 10 mm/0.4 inch Ruler Main reference point The Main reference point is set 10 mm / 0.4 inches inside the ruler in both axes: 1.

  • Page 13: Flexihead With I-Cut

    i-XL Service Guide 4. FlexiHead with i-Cut I-Cut camera 5. MultiCut with i-Cut I-Cut camera...

  • Page 14: I-Cut Camera Connection To Pc

    i-XL Service Guide 6. i-Cut Camera connection to PC A Pixci Sv5 Imaging Board is installed in the front-end pc. The video cable is connected as shown at left. A separate +12V power supply provides power to the camera and the light unit.

  • Page 15: Software Installation

    i-XL Service Guide 8. Software installation Install XL-Guide Insert the XL-Guide CD in the Front end PC. From the XL-Guide CD, start Setup.exe. Follow instructions on screen and install in default directories. You will find more information about software installation in the XL-Guide online help manual. Install i-Cut hardware and software Before installation of i-Cut software can begin, you must complete the following: 1.

  • Page 16: Configure Xl-Guide For I-Cut Control

    i-XL Service Guide If a license update is needed, copy and paste the new control word into the edit box below and press the Add button. Restart i-Cut to enable the updated license. Configure XL-Guide for i-Cut control Ensure the following XL-Guide settings are valid: Parameter Set from Setting...

  • Page 17: How To Check Camera Operation

    i-XL Service Guide 9. How to check camera operation Proceed as follows: 1. From PC Desktop or Start menu, start i-Cut. 2. Observe XL-Guide is started. 3. Switch servo on and complete the Table zero sequence 4. From the i-Cut Calibration menu, select –Check Regmark. 5.

  • Page 18: The Kiss-Cut Knife Tool

    i-XL Service Guide 10. The kiss-cut knife tool A complete kisscut tool consist of: A - The tool body B - Knife adapter C - Locking knob with Pressure unit #1 D - Knife foot E - Knife F - Pressure unit #2 G - Spanner The picture at left shows how to insert the knife into the knife adapter.
  • Page 19 i-XL Service Guide Use the spanner to push the knife into the adapter. Use the spanner also when pulling out the knife from the adapter. The picture shows the knife properly mounted. Now the knife tool is ready to use. The knife depth is controlled by knife pressure.
  • Page 20 i-XL Service Guide Knife pressure is adjusted by turning the Pressure unit knob available on top of the KissCut tool. Adjust and make a test cut to obtain correct setting. If higher knife pressure is needed, interchange Pressure units. Pressure range: Pressure unit #1: 0,3 - 3,5 N Pressure unit #1: 0,8 - 7,5 N...

  • Page 21: Belt Tension

    i-XL Service Guide 11. Belt tension Adjustable Adjustable Adjustable Adjustable The position of the conveyor belt rollers is adjustable: - Adjust the upper rollers to be parallel to the tabletop. - Use the lower rollers for belt tension adjustment. As the adjustment span is limited, it is important you position the rollers in a „middle‟...

  • Page 22: How To Glue The Belt

    i-XL Service Guide 12. How to glue the belt 12.1 Introduction For belt glue, two different procedures are available. If possible, we recommend the procedure introduced November 05, 2007. 12.2 Belt glue procedure, November 05, 2007 Compared to the previous procedure, this is a simplified method where the belt is cut at an angle and glued in one operation.
  • Page 23 i-XL Service Guide Required tooling: Glue applicator (3M EPX, 42446039) Glue tube with nozzles (3M DP-110, 42446021 and nozzle 42446351). Sharp knife 2” wide tape Measuring tape Sand paper Protective gloves Safety glasses (42429050) Note: Glue 3M DP-105 is an acceptable alternative to DP-110.
  • Page 24 i-XL Service Guide Procedure: You can observe that the belt has low friction Smooth in this direction when moving your hand on top of it in one Belt moving direction direction and high friction when moving the opposite direction. Cutting table It is important the belt is mounted onto the table in the indicated...
  • Page 25 i-XL Service Guide Use tape or heavy weight to keep the belt in position. Measure the relevant distances as illustrated in figure 1 and place a ruler along the cut path. Use a sharp knife to cut through both belt materials.
  • Page 26 i-XL Service Guide On both sides, the edge of the belt joint should be smoothly rounded as illustrated at left. Apply glue to the gap. Make sure you have a round top above the belt surface. Note:  Use protective gloves when handling the glue.
  • Page 27 i-XL Service Guide Put a hard, flat material on top of the belt splice. Add some heavy weight. Wait minimum 2 hours for the adhesive to harden. Remove the load and the tape. If necessary, sand the top of the adhesive until the surface is smooth and flat.

  • Page 28: Old Belt Glue Procedure

    i-XL Service Guide 12.3 Old belt glue procedure 12.3.1 Tools you need 1 Milling motor 2 Milling bit, square, 4 mm (see picture at left) 3 Wrenches for the motor chuck 4 Holder for milling motor 5 Superglue 6 Glue gun for melted glue 7 Glue for glue gun 8 Sanding paper...

  • Page 29: Procedure

    i-XL Service Guide 12.3.2 Procedure Smooth in this direction You can observe that the belt has low friction when moving your hand on top of it in one Belt moving direction direction and high friction when moving the opposite direction. It is important the belt is Cutting table mounted onto the table in the...
  • Page 30 i-XL Service Guide Use a straight ruler as a guide when cutting the two belt ends. With adhesive tape, fix one end of the belt. Place an adhesive tape on the table with the adhesive side up as shown.
  • Page 31 i-XL Service Guide Put half of the tape beneath the fixed belt end. Fix the tape. Pull the two belt ends together and fix them with the tape. Use adhesive tape to keep the belt in position.
  • Page 32 i-XL Service Guide Use a Router with a straight router bit, ø4 mm / 0,16 inch. The gap around the bit should be as small as possible to avoid belt material moving up. Make a test cut on a spare piece of belt material.
  • Page 33 i-XL Service Guide Use the Router once more to remove glue and prepare a clean path. Use a vacuum cleaner to remove dust and particles from the path. Fill the path with glue using a hot melt gun. Use a flat and sharp knife to remove superflous glue.
  • Page 34 i-XL Service Guide Use a sanding paper to smoothen the glue surface and make it even with the belt material around. Pay special attention to the edges. Ensure the belt edges are smooth and witout sharp edges.

  • Page 35: Sheet Feeder

    i-XL Service Guide 13. Sheet feeder 13.1 Sheet feeder position Sheet feeder Feeder suction Cutting table This figure illustrates how the feeder paws, the suction cups and the material should meet in order for the paws to grab the material without any collision with the sheet feeder. 13.2 Sheet feeder USB to serial line setup Settings for the serial connection between the PC and the Sheet feeder is:...

  • Page 36: Sheet Feeder Load Table Brackets

    i-XL Service Guide Parameter ( sheet feeder panel ) Setting Pick Additional Travel: 0 ms Hold Length At Pick Time: 3 seconds Carriage Position: 2 mm For optimising of performance to various materials etc, adjustments might be required. For description of each setting, see Sheet Feeder Operators Manual 13.4 Sheet feeder Load table brackets These pictures show how to use the table...
  • Page 37 i-XL Service Guide Picture at left: To release the fixture, push the locking pin. Pictures below: Mount the air knives in front of the stack of material in order to improve sheet separation.

  • Page 38: Air And Vacuum, Blocked Schematic

    i-XL Service Guide 14. Air and vacuum, blocked schematic 14.1 Pressurized air layout when sheet feeder is installed Wall outlet From customer 12174413 12702205 12174447 42443002 42445742 Cutting Sheet table Feeder...

  • Page 39: One Vacuum Pump, Two Vacuum Sections

    i-XL Service Guide 14.2 One vacuum pump, two vacuum sections Vacuum pump Foil feed To sheet feeder Vacuum reverse Vacuum sect. 1 +48V servo on Vacuum sect. 2 controlled Vacuum area 1 Pressurized air, 7 bar Air Pressure Sensor Switch on when pressure > 4 bar Feeder paws down Feeder paws up 2(B)

  • Page 40: Two Vacuum Pumps (Optional)

    i-XL Service Guide 14.3 Two vacuum pumps (optional) 14.3.1 General 14.3.2 3 sections 14.3.3 4 sections...

  • Page 41: Electrical Connections For Camera, Blocked Schematic

    i-XL Service Guide 15. Electrical connections for camera, blocked schematic Coax for camera Carriage Mains outlet, power front view on/off 1, 2 = 12V 3, 4 = GND Camera power 12 = 12V power 11 = GND 4 = 12V 115-230V +12V Light Unit...

  • Page 42: Electrical Schematics

    i-XL Service Guide 16. Electrical schematics 16.1 Table connections i-XL el. schematic 16.1.1 Sheet feeder connections, details 16.1.2 Pressurized air sensor, details 16.1.3 i-XL-20 cable overview 16.1.4 i-XL-24 cable overview 16.1.5 i-XL-44 cable overview 16.1.6 16.2 Sheet feeder Power and safety relay 16.2.1 Motor / drive wiring 16.2.2...

  • Page 43: Mechanical Drawings

    i-XL Service Guide 17. Mechanical drawings 404440 17.1 i-XL20 w/ conveyor 404525 17.2 i-XL20 w/ 2 vacuum sections 404290 17.3 i-XL20 w/ 2 sections and vacuum reverse 404445 17.4 i-XL24 w/ conveyor 404526 17.5 i-XL24 w/ 3 vacuum sections 404435 17.6 i-XL24 w/ 3 sections and vacuum reverse 404515...

  • Page 44: Appendix 1 - I-Cut Production Settings For Kongsberg

    i-XL Service Guide 18. Appendix 1 – i-Cut production settings for Kongsberg This is just one sample to show how to control vacuum and blow back in a manual operation setup. I-FM 0/1 – Sheet feed communication %PMPon/off – starts / stops the vacuum pump %SUCon/off –...

  • Page 45: Appendix 2 - How To Verify And Adjust Correct Angle On A Table With Conveyor Belt

    i-XL Service Guide 19. Appendix 2 – How to verify and adjust correct angle on a table with conveyor belt On machines without conveyor belt, a set of vacuum holes is used as reference when checking the traverse angle. On machines with conveyor belt, the vacuum holes are hidden beneath the belt. This procedure describes one method to verify and adjust the angle: Cutting table Put a sheet of material on the...
  • Page 46 i-XL Service Guide Turn sheet B and insert it into the space as illustrated at left. If the angle is out of adjustment as illustrated at left, use the two red spots as reference when executing the Angle adjust wizard. Laser spot If the angle is out of adjustment the opposite way as illustrated at left,...

  • Page 47: Appendix 3 - Field Installation Of Conveyor Belt Paws And Clamps

    i-XL Service Guide 20. Appendix 3 - Field Installation of Conveyor belt Paws and Clamps 20.1 Pressurized air connections, blocked schematic Vacuum pump Foil feed To sheet feeder Vacuum reverse Vacuum sect. 1 +48V servo on Vacuum sect. 2 controlled Vacuum area 1 Pressurized air, 7 bar...

  • Page 48: How To Put Additional Cables Into The Traverse Beam

    i-XL Service Guide 20.2 How to put additional cables into the traverse beam 1 – traverse beam with air tube. 2 – cut the air tube as indicated. 3 – fix a string to the air tube. 4 – put the string through the traverse by pulling the air tube 5 –...
  • Page 49 i-XL Service Guide String fixed to the air tube. Pull the air tube out in order to pull the string through the traverse beam. Fix cables to the string. Ready to be pulled into the traverse beam.
  • Page 50 i-XL Service Guide Pull the string to move the cables into the traverse.

  • Page 51: Rear Side Of Traverse, Assembly

    i-XL Service Guide 20.3 Rear side of traverse, assembly View nearest to X2 – end of traverse.
  • Page 52 i-XL Service Guide View nearest to X1 – end of traverse.

  • Page 53: Feeder Clamp, X1, Assembly

    i-XL Service Guide 20.4 Feeder clamp, X1, assembly 20.5 Feeder clamp, X2, assembly...

  • Page 54: Appendix 4 - Revolving Work Station, Assembly Procedure

    i-XL Service Guide 21. Appendix 4 - Revolving work station, assembly procedure If not available, drill the fixture holes in the frame beam. Fixture hole information: L = 120 mm / 4.72 inches. W = 258 mm / 10.16 inches. D = 2 x ø9.0 mm / 0.35 inches.
  • Page 55 i-XL Service Guide The next sub-assembly is the pc housing. The picture shows the parts included. Insert the screws as shown. Mount the side brackets to the housing. The side brackets should align with the top of the pc housing. Fix the brackets in this position.
  • Page 56 i-XL Service Guide Mount the pc housing on the frame bracket. Fix the housing to the frame bracket using 8 screws. Put all cables for the operator panel, keyboard, screen, mouse, ON/OFF switch and Emergency stop switch in between the side brackets. Ensure you have all cables in place before continuing.
  • Page 57 i-XL Service Guide Raise the beam towards the pc housing and fix it using one T-slot nut entered from above. Ensure the beam is exactly vertical. If not, loosen the T-slot nut carefully and adjust the beam until perfect. Then fix the beam to the pc housing using all four T-slot nuts.
  • Page 58 i-XL Service Guide Fix the top disk to the beam as shown. It should be possible to turn the disk afterwards. Therefore, leave the screws with a tiny gap. Lock the screws using Loctite 243. Fix the top frame to the top disk. Mount all cables for MCU, switches, screen, keyboard and mouse nicely from the beam and up.
  • Page 59 i-XL Service Guide Assemble the cables in a nice way beneath the top frame.

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