Esko Kongsberg XE10 User Manual
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Esko Kongsberg XE10 User Manual

Kongsberg xe / i-xe series, digital cutting table
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Kongsberg XE
User Manual
09 - 2017 | Kongsberg XE

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  • Page 1 Kongsberg XE User Manual 09 - 2017 | Kongsberg XE...

  • Page 2: Table Of Contents

    Kongsberg XE Contents 1. Preface................................. 7 2. Change Record............................8 3. Welcome..............................9 4. Using this manual........................... 10 4.1 Main Sections........................... 10 4.2 Name Styles and Symbols.......................11 4.3 Pictures and Illustrations.........................11 4.4 Local Languages..........................12 4.5 About Xx-Guide dialogs........................12 5.
  • Page 3 Contents 6.4 Operators Panel..........................24 6.5 Pressurized Air system........................26 6.6 Application programs available.......................27 7. XE-Guide..............................28 7.1 The Graphical User Interface......................28 7.2 The Main Menu..........................28 7.3 The Main Toolbar functions......................30 7.4 File View............................31 7.5 File View toolbar..........................32 7.6 Job View.............................34 7.7 Job View toolbar..........................
  • Page 4 Kongsberg XE 11.1 Introduction............................ 56 11.2 Speed Setup............................57 11.3 Table Acceleration.......................... 57 11.4 Table Speed............................ 57 11.5 Jog Settings............................. 58 11.6 Table Setup............................. 58 11.7 Set Reference Point........................59 11.8 Set Ruler Position...........................60 11.9 Set Table Top Reference........................ 60 11.10 Map Table Top Surface........................ 61 11.11 Register Table Size........................
  • Page 5 Contents 15.2 Tool Configuration..........................88 15.3 Adjust Active Tool...........................89 15.4 Lag Settings (for Rotating Tools)....................90 15.5 Tool Height Calibration........................92 15.6 Rotation Adjustment (for Rotating tools)..................92 15.7 Center Offset Adjustment......................93 15.8 Manual adjustment of Center Offset and angle................. 94 15.9 Tool Offset............................95 15.10 Maintain Tool List (More...)......................96 16.
  • Page 6 Kongsberg XE 20.4 i-cut..............................133...

  • Page 7: Preface

    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 8: Change Record

    Kongsberg XE 2. Change Record Date Description dd-mm-yy 09-02-2014 jhbe First edition of this document 12-01-2017 JHBE Updated version of this document 13-06-2017 jhbe Psaligraphy Knife tool added 05-09-2017 jhbe PressCut chapter updated.

  • Page 9: Welcome

    Kongsberg XE 3. Welcome Welcome to the User Manual for Kongsberg XE / i-XE. This manual will provide a complete and detailed description of all XE / i-XE functions. It is aimed for operators of Kongsberg Cutting Tables and people preparing files for such equipment.

  • Page 10: Using This Manual

    Kongsberg XE 4. Using this manual 4.1 Main Sections The manual is divided into the following Main Sections: Safety Regulations • All safety related issues are discussed. System Description • This chapter provides basic knowledge about the machine. Basic Operations •...

  • Page 11: Name Styles And Symbols

    Kongsberg XE • This chapter describes maintenance to be carried out by the customer. Fuse Replacement • Fuse location and specification. Appendices • FAQ - Frequently Asked Questions 4.2 Name Styles and Symbols Name or style Description Pop-up dialog This is the dialog that appears when you click the Right mouse button.

  • Page 12: Local Languages

    Kongsberg XE 4.4 Local Languages This manual is available in a wide range of local languages. Screen pictures and illustrations remains in English language. 4.5 About Xx-Guide dialogs To exit from any Xx-Guide dialog, use the control buttons available. Using the cross in upper right corner is not recommended and the consequence is un- predictable.

  • Page 13: Safety Regulations

    Kongsberg XE 5. Safety Regulations 5.1 Introduction The table is designed to conform to Safety Regulation standards. Nevertheless, operating the table can involve hazards if: • The operator does not follow the Operating Instructions. • The table is used for Non-intended purposes. In addition to the Safety Regulation described below, you will find safety warnings in the respective topics.

  • Page 14: Requirements To Be Met By Operators

    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 resulting from such non-intended use.    5.5 Danger Zones 5.5.1 Danger Zones...

  • Page 15: Moving Parts, Laser Radiation And High Voltage

    Kongsberg XE 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 5.5.3 Loose Clothing While working with this machine, do not: •...

  • Page 16: Noise Level

    Kongsberg XE • Use scarfs 5.5.4 Noise Level • Hearing Protection should be used by any personnel exposed to the noise from the machine. 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.

  • Page 17: Safety Devices

    Kongsberg XE 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: •...

  • Page 18: Main Power Switch

    Kongsberg XE Device no Description Main Power Switch Emergency Stop Button Warning Lamp / Status Lamp Photo cell supervision, Dynaguard Traverse Stop Switches, Dynaguard 5.7.2 Main Power Switch The Main Power Switch turns power to the table on/off. 5.7.3 Emergency Stop Button Switch positions: - Emergency Stop is switched OFF.

  • Page 19: Warning Lamp On Top Of Y Carriage

    Kongsberg XE Note: Activating the Emergency Stop Button does not provide a guarantee against injury! Due to the high kinetic energy of moving parts, do not underestimate Stop Distance of traverse, Y carriage and Tool Head. 5.7.4 Warning Lamp on top of Y Carriage Light is Description Off...

  • Page 20: Protective Equipment

    3. Observe that Servo Power is switched on, 4. Press Start to continue. 5.8 Protective Equipment For the operator(s), Esko recommends the following Protective Equipment: Close-fitting clothes to avoid being caught by the beam or the tool head which can cause injuries.
  • Page 21 Kongsberg XE Traverse end The low part of the traverse ends is un- protected. Actions: • Children are not supposed to be in the machine area. • Do not work or stay beneath the traverse while the machine is working. Y-carriage The top of the Y-carriage is un-protected in all four directions.
  • Page 22 Kongsberg XE Traverse Beam The DynaGuard Safety System photo cell beam c will stop the movement when hit. Actions: • Stay out of this area while the machine is working.

  • Page 23: System Description, Xe

    Kongsberg XE 6. System Description, XE 6.1 Introduction 6.2 Naming conventions Machine 1 Cutting Table 5 Air Pressure Regulator 2 Traverse 6 Emergency Stop button 3 Y carriage 7 Operator Panel 4 Tools 8 Main Power on/off switch 5 Main Power Unit (MPU) 9 Traverse Safety Stop switches (DynaGuard) Axes X - X-axis...

  • Page 24: Main Power Switch

    Kongsberg XE X1 - X1 end of traverse X2 - X2 end of traverse 6.3 Main Power Switch Switch positions: - the Main Power to the machine is switched OFF. - the Main Power to the machine is switched ON. 6.4 Operators Panel Power On Mains Power on/off...
  • Page 25 Kongsberg XE 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 26: Pressurized Air System

    Kongsberg XE Tool Down Press the Tool Down button to manually operate the machine with a tool in the down position. Cancel by pressing Tool Down a second time. Vacuum release mode For details about this function, see separate chapter 'Vacuum control'. If activated for more than 2 seconds, this button activates the Manual Belt Clamp function.

  • Page 27: Application Programs Available

    Kongsberg XE 6.6 Application programs available After installation of XE-Guide, the following application programs are available XE-Guide Control program for the Cutting Table SysLoad Program for download of updates to CU–modules HWT800 Hardware test program, see separate HWT800 User Manual.

  • Page 28: Xe-Guide

    Kongsberg XE 7. XE-Guide 7.1 The Graphical User Interface The XN Graphical User Interface (GUI) contains these main elements: 1 Main Menu 5 Preview 2 Main Toolbar 6 Job View Toolbar 3 File View Toolbar 7 Job View 4 File View 8 ARS Toolbar  ...
  • Page 29 Kongsberg XE The following functions are available from Main Menu and sub-menus: File Open Open an Input File. Create a box Work with 123Box. Exit Terminate Xx-Guide. View Position Display Display of table positions and parameters. View Messages Message Display; provides a log of system messages. Customize File View File View configuration.

  • Page 30: The Main Toolbar Functions

    Kongsberg XE User Manual A link to this document. 7.3 The Main Toolbar functions The left part of the Main Toolbar contains the following general functions:  Selects application from the drop down list. View the Message Display. Enter Tool Configuration. Set Single Design operation.

  • Page 31: File View

    Kongsberg XE Shows measured thickness of material on the table. Rewinds current job. T:  Estimated total job time. R:  Estimated remaining job time. Main Toolbar configuration From View->Toolbars, you can configure the Main Toolbar to show left / right / none of the Main toolbar.

  • Page 32: File View Toolbar

    Kongsberg XE The file name is always displayed in column 1. The other 4 columns can be customized in the Customize File View dialog.   The files in the File View are sorted in normal or reversed order. The sorting is toggled by clicking the header of the columns.
  • Page 33 Kongsberg XE You will find the following buttons in the File View toolbar: Opens selected file. Selects disk drive for input files. Up one level. Shows file names only. Shows file names and details. Auto Open function Enable Move Finished File – mode. Moves the current job, when finished, to a sub-directory and removes it from the list of files in the File View.

  • Page 34: Job View

    Kongsberg XE 7.6 Job View When you open a file, the design is displayed in the Job View window.   Designs placed in Job View can be manipulated according to the selected layout mode. Various display options are available from the Job View toolbar.   The File Information Bar on top of Job View display some parameters regarding the last Input File opened.

  • Page 35: Job View Toolbar

    Kongsberg XE 7.7 Job View toolbar Show Job view in full screen. When in full screen display, the button face changes to this: Show Job view in split screen. Enters zoom mode. The cursor changes to a magnifying glass. Select area to be zoomed.
  • Page 36 Kongsberg XE Rotate direction of flute (corrugated) or grain (folding carton). Rotate direction of flute (corrugated) or grain (folding carton). Automatic Register System (ARS). Register to sheet edge. Enables XL-register functions. The select reference functions are disabled. Select Reference point from the drop down list. Select a Job Setup file from the drop down list.

  • Page 37: Preview

    Kongsberg XE 7.8 Preview A single click on a file in File view will display the job in the Preview window. 7.9 Status bar The status bar at the bottom of the GUI shows brief descriptions of various functions in the GUI.

  • Page 38: Critical Warning Display

    Kongsberg XE 7.10 Critical Warning Display When a situation occurs that requires an action from the operator, the following message box will be displayed: Additional information may be found in the Message Display: 7.11 Message Display The Message display is available from the Main Toolbar button. The Message display offers additional information when troubleshooting the system.

  • Page 39: Position Display

    Kongsberg XE Always on top Check this box if you want the Message display to stay on top. Log messages The system is prepared for output of additional system information, useful for service and troubleshooting. For normal operation disable this function to reduce the amount of messages. Show The type of information displayed in the Message display can be configured to: 1.

  • Page 40: Accelerator Keys

    Kongsberg XE Tool Rotation and Z - axes Display Z and Tool Rotation positions. • Z shows actual distance from Z axis zero position • Tool Rotation shows actual angle from Tool Rotation zero • Material thickness shows measured thickness of material on the table Encoder count, X and Y Shows encoder input as read for X1, X2 and Y encoders Encoder count, Z and Tool Rotation...
  • Page 41 Kongsberg XE Function Ctrl + S Step And Repeat setup Ctrl + T Tool Configuration     Help in active window     Ctrl + Alt + D Memory dump Ctrl + Alt + L Servo Log Ctrl + Alt + O System Setup Ctrl + E Display axis force...

  • Page 42: Basic Operations

    Kongsberg XE 8. Basic Operations Keep away from Moving Parts during operation. Do not lean on Racks, Guide Ways or Traverse during operation, as this may cause personal injury. Before starting any operation, make sure that: • The Table is free from obstructions •...

  • Page 43: Reset Safety System

    Kongsberg XE Servo Power Press the Servo On pushbutton. The Warning Lamp on top of the Y carriage should be on without flashing. Table Zero Sequence Press Start pushbutton to complete the Table Zero Sequence. The machine will move to the Selected Reference Point. The table is now ready for operation.

  • Page 44: Continue After Safety Break

    Kongsberg XE 8.5 Continue after Safety Break If the Safety System is activated, all movements on the table are stopped and the Warning Lamp starts flashing. To continue operation, proceed as follows: Ensure the table is free from obstructions and ready for operation. Reset the Safety System by pressing the Pause pushbutton.

  • Page 45: Prepare For A Job

    Kongsberg XE 9. Prepare for a Job 9.1 Introduction Keep away from Moving Parts during operation. Do not lean on Racks, Guide Ways or Traverse during operation, as this may cause personal injury. Before starting any operation, make sure that: •...

  • Page 46: Board Setup

    Kongsberg XE 9.3 Board Setup Position the material for the job on the table. Select Board Size from the Board Size drop down list.   Note : Board size information is used for calculating Step & Repeat. If Step & Repeat is not used, this setup is optional.

  • Page 47: Flute/Grain Direction

    Kongsberg XE 9.5 Flute/Grain Direction Use the Toggle Flute Direction button to set correct direction for the actual job. Verify that the Flute/Grain Direction corresponds to the material. 9.6 Vacuum Section Selection From the Vacuum Section setup – dialog, configure a suitable vacuum area for the job. Select Vacuum Sections that corresponds to the outline of your material.

  • Page 48: Job Execution

    Press Vacuum On to start the vacuum pump. Press Start to execute the job. 9.9 Corrugated production Corrugated Production without Registration Marks is straight forward following the procedure described in the Prepare for a Job - chapter. Recommended tooling is described in Esko Tooling Guide.

  • Page 49: Folded Carton Production

    Kongsberg XE 9.10 Folded Carton Production Introduction Using a matrix for folding carton sample making is a two-step process: 1. Prepare the matrix B with a channel underneath each crease line. 2. Place the material to be processed on top of the matrix and execute the program. An exact crease line is prepared when the material is forced down into the matrix channel.

  • Page 50: Make A Pen Plot

    Kongsberg XE • Press Start to execute the job.   • Enable the Matrix Function. • In the same dialog: • • Select the Fixed value radio button • Enter the thickness of the matrix material in the corresponding field. •...

  • Page 51: How To Procedures, Advanced

    Kongsberg XE 10. How To Procedures, Advanced 10.1 Jobs including Reverse Score Step 1 - the sheet is aligned towards the Right Step 2 - the sheet is aligned towards the Left Ruler. Ruler. Reverse Operations are completed. A typical use of Reverse Score is when you want to add a Crease line on the front side of a material that you normally prepare from the rear side.

  • Page 52: Different Reference Point Settings

    Kongsberg XE 10.2 Different Reference Point settings To define or modify reference point settings, go to the Set Reference point wizard. Reference points are selected from the Job View Toolbar. 10.3 Change Tool in a Job Sometimes, you would like more tool combinations than available in the tool head.   This document describes through one example how this can be solved by using two different job setup files:  ...

  • Page 53: Work With Register Bar

    Kongsberg XE Insert the knife tool in the tool head and run the same job. 10.4 Work with Register Bar The Register Bar is an aid when the material needs registrations that fits the requirements of a specific printing press or die cutter. On XN, the register bar is mounted along the X - axis as illustrated at left.
  • Page 54 Kongsberg XE • When both positioning pins are in place, the sheet is correctly positioned. • Switch Vacuum on. IMPORTANT: Remove the Positioning pins. Now, the machine is ready for operation. Reference point setting When working with register bar, select one of the available Reference points (Option->Table options) and set a reference point in a fixed position relative to one of the...
  • Page 55 Kongsberg XE This work flow ensures exact positioning of the geometry relative to the Positioning pins.

  • Page 56: System Setup

    Kongsberg XE 11. System Setup 11.1 Introduction This chapter will explain functions and parameters that are important for the XE-system to run properly. Examine each step carefully to ensure proper settings: One time adjustments completed at the factory To be repeated if necessary. Adjust X1 to X2 Angle Register Table Size Set Ruler Position...

  • Page 57: Speed Setup

    Kongsberg XE 11.2 Speed Setup Main Menu->Options->System Option->Speed Setup Ctrl+Alt+O 11.3 Table Acceleration Options->System Option->Speed Setup->Acceleration Use this setting to reduce the overall acceleration on the machine. 11.4 Table Speed Select between High Quality, Normal or High Speed mode (Options->System Option- >System).

  • Page 58: Jog Settings

    Kongsberg XE 11.5 Jog Settings Continuous Jog speed Options->System Option->Speed Setup->Jog Speed The Continuous Jog Speed can be reduced to a % value of the maximum jog speed: Enter the wanted value in the low Jog Speed edit box. Enter the wanted value in the high Jog Speed edit box. Incremental Jog Step Size Options->System Option->Speed Setup->Incr.

  • Page 59: Set Reference Point

    Kongsberg XE 11.7 Set Reference Point Main Menu->Options->Table Option->Set Reference point Use this wizard to establish Reference Points. The Main Reference Point is a fixed position on the Cutting Table marked as a cross of drilled holes. The Set Reference point wizard is an aid for adding or changing the table reference points. Procedure: Press the Set Reference Points button to set up any fixed reference points.

  • Page 60: Set Ruler Position

    Kongsberg XE 11.8 Set Ruler Position Main Menu->Options->Table Option->Set Ruler position 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 procedure if mechanical maintenance has been carried out on the table or traverse.

  • Page 61: Map Table Top Surface

    Kongsberg XE 11.10 Map Table Top Surface Main Menu->Options->Table Option->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.

  • Page 62: Vacuum Control

    Kongsberg XE 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. 11.13 Vacuum Control Options->System Option->Table Setup->Vacuum Control Note: Vacuum quick release and vacuum section selection will not work before the Vacuum push-button on the Operator Panel has been operated once.

  • Page 63: System Options

    Kongsberg XE Vacuum is switched on using the Vacuum on push-button. If no job is started within 30 min. after the vacuum is switched on, the vacuum pump is switched off automatically (E). A job is started. The vacuum pump will be started automatically. The job is finished.

  • Page 64: Display Units

    Kongsberg XE 11.15 Display Units Options->System Option->System->Display units Select unit to be used for the GUI. 11.16 Language Options->System Option->System->Language Select language for the GUI. 11.17 Input File Options->System Option->System->Input File format...
  • Page 65 Kongsberg XE Input file formats Select one of the available formats in the drop down list. ACM is the standard CAM format. The formats available are: File extension Description .acm Kongsberg acm – format. This is the default input format for Kongsberg XP. Described in the Technical Reference manual for XP.

  • Page 66: Optimization

    Kongsberg XE 11.18 Optimization Options->System Option->System->Optimization Sequencing This function will sort the input file in order to minimize tool changes. The execution order will be determined by the tool type, so that pen is executed before crease which is executed before knife. Some functions depends upon sequencing being active, as reverse score.

  • Page 67: Vacuum Setup

    Kongsberg XE Maximum allowed arrow height value is 0.2 mm / 0.08 inch. This setting will have impact on the performance regarding speed and quality. 11.19 Vacuum Setup 11.19.1 Vacuum Section Configuration Pressing the Vacuum Setup - button opens up a new dialog where the vacuum section configuration for the actual machine is specified.

  • Page 68: Display Color

    Kongsberg XE Set park position in current position. Press this button to established a park position in current laser pointer position. Park position at end of job The park position is in the lower right corner of the rectangle enclosing the job. 11.21 Display Color Options->System Option->System->Display Colors This dialog defines what colors to be used for each line in Job...

  • Page 69: Change Flute/Grain Direction

    Kongsberg XE The list of available board sizes is maintained from the Board size dialogue. To edit already defined boards, edit the values directly in the table. To add new boards, go to the last line in the table and add the new material to the empty line. Press the Apply button to save the new values.
  • Page 70 Kongsberg XE Main Menu->Options->Transformation Pop-up dialog in Job View Ctrl + Alt + T Scaling X/Y Enter a % value in the edit box to scale the design. A value less than 100 will decrease the size, and a value greater than 100 will increase the size of the design.

  • Page 71: Step And Repeat

    Kongsberg XE Use the table below to calculate the angle from a simple measurement. In a distance L from the lower left corner, measure the deviation from the horizontal line (d). Find the corresponding d – value in the table below and read the angle v in degrees.
  • Page 72 Kongsberg XE Pop-up dialog in Job View Use this function to create multiple copies of a job. T - Trim (distance from sheet edge). G - Gap (distance between each item). Execute one at a time This function depends upon Sequencing being enabled. When enabled, one and one design is completed.

  • Page 73: Counter Setup Dialog

    Kongsberg XE 11.26 Counter setup dialog Main Menu->Options->Counter Setup File View Toolbar->Matrix This function is available when Application is set to Folding Carton. The Counter function is used when the job is executed on top of a matrix. The purpose of this function is to avoid cutting through the matrix.
  • Page 74 Kongsberg XE The Counter function is enabled.

  • Page 75: Reference Points And Coordinate System

    Kongsberg XE 12. Reference Points and Coordinate System All X and Y coordinates in the Input File uses the selected Reference Point as origin.   Two modes of operation are available:   Fixed reference point Select a Reference Point from the Select Reference point drop down list. Panel reference point •...
  • Page 76 Kongsberg XE • A full working area. • Correct sheet feed operation. • Correct handling of long jobs Using the Main reference point during program execution ensures correct operation. The Main Reference point for i-cut For i-cut to run properly, the Main Reference point should be set in a specific position on the table, using i-cut reference point setting wizard (79).
  • Page 77 Kongsberg XE When you use the lower 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 lower right ruler is normally used for reverse score operations. At the same time the direction of the X axis is reversed.

  • Page 78: Job Setup

    Kongsberg XE 13. Job Setup 13.1 Introduction Job Setup is a table that links Logical tool numbers (P - numbers) in the Input File to tools on the machine and describes their behavior.   The Job Setup information is stored as a file on the front end PC.   Notes •...

  • Page 79: Job Setup Parameters

    Kongsberg XE 1. Job Setup is edited line by line. The parameters are described below. 2. When finished editing, use the Apply function to save to current or to a new file name. 3. Each line in Job Setup can be tested using the Test Line function. Follow the instructions in the dialog.
  • Page 80 Kongsberg XE Across the flute Entering a positive value specifies a depth measured from the top of the material, but: • For knife cutting, a value = 0 specifies through-cut. • For pen, crease, drill and router, a value = 0 specifies the top of the material. If you specify a T+/- value, the value specifies a distance from the cutting underlay.

  • Page 81: Extended

    Kongsberg XE Test line n Select this function to execute a test figure with the selected tool n. The figure executed is a square 40 x 40 mm (1.6 x 1.6 inches). Use this function as a quick way to verify correct adjustments for the different tools. Circle adjustment line n The Circle lag parameter determines the quality of circles when cutting with knife.

  • Page 82: More

    Kongsberg XE Reverse Score Enable this check box to specify that the tool shall work on the front side of the material. Stop Before Use When this function is enabled, the execution will stop at the beginning of this line and an operator message is displayed.
  • Page 83 Kongsberg XE The following functions are available: OverCut Check this box to enable or disable the Knife Over-cut function. Applies to knife tools only. Specify the size of the over-cut at start and end of consecutive cut lines. When the direction change between two consecutive lines is bigger than 13.5 degrees, an over-cut corner action is performed.
  • Page 84 Kongsberg XE Extra lift of tool Add extra lift height to tools when moved in up position. Useful for warped boards or uneven surfaces.

  • Page 85: Job Layout

    Kongsberg XE 14. Job Layout 14.1 Introduction The system can operate in either Single Design Layout mode or Multi Design Layout mode Single Design Layout Press the Single Design Button to select Single Design layout mode. When a design is opened in this mode it is always located relative the selected reference point.

  • Page 86: Job Layout Setup

    Kongsberg XE Note: All functions described here are available from Main Menu->Layout and from the Pop-up menu in Job view. Select a design A selected design is always shown in pink. After a design is opened it is always selected. It can also be selected by clicking on a line in the design or holding the left mouse button down and drag a square over the designs to select.
  • Page 87 Kongsberg XE Snap The snap function is turned on and off by ticking the radio buttons on and off. Snap distance When the snap function is on, a design will be snapped to another design if it is positioned closer than the snap distance. Gap between designs This parameter defines the distance between designs after a snap function is completed.

  • Page 88: Tool Configuration And Adjustment

    Kongsberg XE 15. Tool Configuration and Adjustment 15.1 Combination of Tools The XE / i-XE machine is equipped with two general tool positions. Some restrictions applies regarding the combination of different tools. Use this cross-reference table to search possible combinations: PressCutStatic HiForce VibraCut...

  • Page 89: Adjust Active Tool

    Kongsberg XE Main Toolbar->Tool Configuration Main Menu->Option->Tool Configuration Ctrl + T The Tool Configuration dialog is used for all tool settings and adjustments. The Tool Type mounted is identified by hardware codes inside each tool. Current tool configuration is displayed under Identified tools. When a new tool is inserted, it will be identified to the system automatically.

  • Page 90: Lag Settings (For Rotating Tools)

    Kongsberg XE 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: We recommend using a sheet of Folded Carton material, 5-6 mm / 0.2 inch, when executing the adjustments.
  • Page 91 Kongsberg XE Lag Setting Lag – lag value. This is the distance from the rotation center to 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.

  • Page 92: Tool Height Calibration

    Kongsberg XE Circle Lag   Circle quality is determined by a parameter called Circle Lag. The parameter value will vary depending upon the actual material. Therefore, the adjustment is located in the Job Setup dialog. 15.5 Tool Height Calibration C systems are equipped with Automatic Tool Height Calibration. Thus, the system will run without any manual height calibration.

  • Page 93: Center Offset Adjustment

    Kongsberg XE 1. Select the Tool to be adjusted. 2. Press the Adjust Active Tool button to enter the wizard selection dialog. 3. Select Rotation adjustment. 4. Follow the instructions given by the wizard, step by step. 5. Repeat the procedure for all Tools mounted.   Manual Adjustment 1.

  • Page 94: Manual Adjustment Of Center Offset And Angle

    Kongsberg XE 1. Put an appropriate test material, that means a thin paper on the table (any significant material thickness will create a misleading offset in this wizard). 2. Switch vacuum on. 3. Select the Tool to be adjusted. 4. Press the Adjust Active tool button to enter the wizard selection dialog. 5.

  • Page 95: Tool Offset

    Kongsberg XE Sometimes, it might be necessary to fine-tune the adjustments obtained using the wizards. Use this dialog to modify the adjustment values for angle and center offset. 1. Select the tool to be adjusted. 2. Press the Manual adjustment of…. button to enter the adjustment dialog. 3.

  • Page 96: Maintain Tool List (More

    Kongsberg XE 2. Select the Tool to be adjusted. 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.

  • Page 97: Tooling System

    Kongsberg XE 16. Tooling System Knife Blades are extremely sharp. Take care when handling Knife Tools. Laser Radiation. Do not stare into beam! The tool head is equipped with a class II laser pointer. Emitted laser power < 1 mW. 16.1 Introduction Knife Blades are extremely sharp.

  • Page 98: How To Replace A Tool

    Kongsberg XE 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 temporarily or for storage. •...
  • Page 99 Kongsberg XE 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 the machine.

  • Page 100: Presscut Knife Tool

    Kongsberg XE 16.5 PressCut Knife Tool The PressCut Knife Tool is a special knife tool for vinyl cutting. The Cutting Depth is controlled by the downward knife pressure. The pressure is adjustable from Selected Job->Edit Layer dialog. For applications where a more accurate depth control is required, a simple foot solution is available.
  • Page 101 Kongsberg XE A special hand tool is available as an aid when replacing Knife Blades. Use this hand tool when 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.
  • Page 102 Kongsberg XE The knife pressure is modified if Speed Dependent Tool Pressure is specified, see below. The Knife Pressure specified in the Layer structure is automatically adjusted. During the tool down movement, the PressCut Knife Tool moves down until the material surface is detected and the proper Knife Pressure is achieved.

  • Page 103: Static Knife Tool

    Kongsberg XE Foot solution Normally, the PressCut Knife Tool is used without the foot mounted.   When the foot is mounted, the Cutting Depth d is controlled by the adjustable screw S. Procedure: 1. Press clamp C as indicated to lock the Knife Shaft.

  • Page 104: Vibracut Knife Tool

    Kongsberg XE Replace knife blade Loosen screw A and replace the knife blade as shown at left. Push the knife blade down as the screw is fixed. Tool Adjustment For this tool, complete the following adjustments: Adjustment Description Tool Height Correct tool height relative to table top Lag Setting Nominal value is 0.
  • Page 105 Kongsberg XE Running with 6000 RPM and amplitude +/- 0.15 mm (0.006 inches), this tool is recommended for light duty Corrugated Materials. High Frequency VibraCut knife tool Running with 12000 RPM and amplitude +/- 0.6 mm (0.024 inches), this tool is recommended for more demanding Corrugated Materials.
  • Page 106 Kongsberg XE 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. Extreme care should be taken when inserting the Knife Foot again. Keep fingers away from Knife Blade as illustrated at left.

  • Page 107: Varicut Knife Tool

    Kongsberg XE 16.8 VariCut Knife Tool Introduction VariCut is a special knife tool for applications where the accuracy of the cutting depth is critical. The foot is floating on top of the material. The cutting depth depends upon how far out from the foot the knife extends. The cutting depth is configurable from the XE-Guide Job setup dialog.
  • Page 108 Kongsberg XE Loosen the screw for blade fixture. Insert a new knife blade into the holder. Carefully push the blade towards the bottom of the slit as the screw is fixed. Tool Adjustment For this tool, complete the following adjustments: These adjustments are carried out with the foot removed: Adjustment Description...
  • Page 109 Kongsberg XE A prerequisite for correct operation, is that the zero reference for the knife is properly adjusted. There is a separate 'Height adjust wizard' available for the VariCut tool. Using this wizard should provide a proper setting. If you want to fine tune the depth setting even more, a manual method is described here: •...
  • Page 110 Kongsberg XE For fine adjustment, proceed as follows: 1. Use a sheet of carton with known thickness 2. On the cutting table, place the carton on top of a sheet of paper as illustrated at left. 3. Prepare a job setup file with P1 = VariCut and specify a cutting depth = t.

  • Page 111: Hi-Force Knife Tool

    Kongsberg XE 16.9 Hi-Force Knife Tool The Hi-Force Knife Tool is a general purpose knife tool suitable for cutting a wide range of materials. As the name indicates; this tool is prepared for a higher tool pressure compared to the Static Knife Tool.
  • Page 112 Kongsberg XE 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. Extreme care should be taken when inserting the Knife Foot again. Keep fingers away from Knife Blade as illustrated at left.

  • Page 113: Psaligraphy Knife

    Kongsberg XE To remove the Knife Adapter, just pull it out from the holder. 16.10 Psaligraphy Knife Note: In XE-Guide, this tool is treated as a Hi-Force Knife Tool. Psaligraphy Knife is a tool for cutting of fine details in paper and folding carton.

  • Page 114: Rotacut Knife Tool

    Kongsberg XE Replace Knife Blade For Knife Blade change, remove the foot. Note: Be extremely careful when mounting the foot. The locking screw will always point towards the cutting direction Tool Adjustment For this tool, complete the following adjustments: Adjustment Description Lag Setting The Knife Lag depends upon the Blade Adapter.
  • Page 115 Kongsberg XE The RotaCut Knife Tool 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: •...
  • Page 116 Kongsberg XE Observe the Guide Pin in the foot and the groove in the Tool Shaft.   Position the foot onto the Tool Shaft as shown at left.   Push the foot into position. A self-locking mechanism ensures the foot is kept in place.
  • Page 117 Kongsberg XE Be careful, though, not to adjust the cutting depth too deep into the Cutting Underlay (figure at left). U - cutting underlay M - material D - X/Y moving direction Tool Setup for RotaCut Knife Tool Correct setting of Lag- and Width - values are shown.

  • Page 118: Multi-Function Unit

    Kongsberg XE 16.12 Multi-Function Unit 1. Tool Height Measuring tool 2. Ballpoint Pen / Ink Tool 3. Laser spot 16.13 Ballpoint Pen / Ink Tool The The Ballpoint Pen Tool is available for pen drawing. Tool pressure is adjustable by a knob on top of the tool.
  • Page 119 Kongsberg XE Replace tool Turn the pen tool bracket clockwise to release the pen. Remove the pen tool from the pen holder. After the Ballpoint pen insert has been replaced, insert the pen tool into the pen holder and turn the bracket counter-clockwise to engage the pen tool again.

  • Page 120: Measuring Foot

    Kongsberg XE Koh-i-Noor Ink Tool From left: • Sealing - to be used when the tool is out of use. • Koh-i-Noor pen tool • Koh-i-Noor pen insert • Locking knob. Tool Adjustment For this tool, complete the following adjustments: Adjustment Description Tool Height...

  • Page 121: Laser Pointer

    Kongsberg XE 2. Map Table Top Surface. No adjustments are necessary. 16.15 Laser Pointer The Laser Pointer (3) 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.

  • Page 122: Maintenance

    Kongsberg XE 17. Maintenance More information about maintenance is available in the Maintenance Manual. Warning Main Power should be switched off before cleaning is carried out. 17.1 Daily maintenance • Inspect the equipment in order to prevent any irregularities. • The table surface should be kept clean at all times. •...

  • Page 123: Fuse Replacement

    Kongsberg XE 18. Fuse replacement Before starting the Fuse Replacement procedure: • Switch Power Off using the Main Power Switch • Remove the Main Power plug from the wall socket 18.1 MPU MPU Location Note: MPU location is model dependent. All fuses are located on the rear side of the Main Power Unit (MPU).
  • Page 124 Kongsberg XE Fuse Details Fuse name 115V 230V Main power fuse F1 and F2 T 10A 250V (5x20 mm) T 5A 250V (5x20 mm) T 6,3A 250V (5x20 mm) T 6,3A 250V (5x20 mm) T 15A 250V (5x20 mm) T 15A 250V (5x20 mm) MPU Fuses (MPU 32562308) Fuse Location Fuse Details...
  • Page 125 Kongsberg XE 18.2 X1 X1 Amplifier Location Fuse Location Procedure 1. Remove X1 cover 2. Remove fuse Fx1, check with ohm - meter. If blown, replace with a new identical fuse. 3. Replace X1 cover. 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)

  • Page 126: Y/Z Fuse

    Kongsberg XE 18.3 X2 X2 amplifier Location Fuse Location Procedure 1. Remove X2 cover 2. Remove fuse Fx2, check with ohm - meter. If blown, replace with a new identical fuse. 3. Replace X2 cover. 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) 18.4 Y/Z fuse...

  • Page 127: Tool Rotation/Reciprocating Knife/Tool Up_Down

    Kongsberg XE Y/Z amplifier Location Fuse Location Procedure 1. Remove Y cover 2. Remove fuse Fy or Fz, check with ohm - meter. If blown, replace with a new identical fuse. 3. Replace Y cover. 4. Insert main power cable into the wall socket and turn main power ON Fuse Details Fy: T 8A 250V 1 1/4 x 1/4 in (6,3 x 32 mm) Fz: T 2A 250V 1 1/4 x 1/4 in (6,3 x 32 mm)
  • Page 128 Kongsberg XE Tool Board Location Fuse Location Fhr - Tool rotation fuse. Fu/d - Tool up/down or tool reciprocation fuse. Procedure 1. Fuses are available on the Tool Board inside the actual tool. 2. Remove the plastic cover on the tool. 3.
  • Page 129 Kongsberg XE Hi-Freq VibraCut knife Vib. Fu/d T 4A 125V NANO (42444828) tool Presscut knife tool Tool rotation T 2A 125V NANO (42441618) Presscut knife tool Tool u/d Fu/d 0.75 T 0,75A 125V NANO (42442541) RotaCut Tool rotation T 2A 125V NANO (42441618) RotaCut Knife RPM Fu/d...

  • Page 130: Install Software

    Kongsberg XE 19. Install software For information about software installation, see the Installation Manual for the actual machine. Available on the Documentation DVD.

  • Page 131: Frequently Asked Questions

    Are 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 to be the amplifier board malfunctioning.

  • Page 132: Xx-Guide

    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 head.
  • Page 133 Kongsberg XE If there was a software update recently, check if the firmware on the machine and Xx-Guide are of the same version Check the serial connection between PC and MCU Check the connection at the emergency button 20.4 i-cut Outside table limit Check your starting point.

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