Esko Kongsberg V-Series User Manual
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Esko Kongsberg V-Series User Manual

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Kongsberg V-series
User Manual
09 - 2017 | V-series

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  • Page 1 Kongsberg V-series User Manual 09 - 2017 | V-series...

  • Page 2: Table Of Contents

    Kongsberg V-series 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 5. Safety Regulations..........................13 5.1 Introduction............................13 5.2 Responsibilities..........................
  • Page 3 Contents 6.4 Variable Blow Back...........................27 6.5 Pressurized Air system........................28 6.6 Application programs available.......................28 7. Basic Operations............................30 7.1 Power On Sequence........................30 7.2 Reset Safety System.........................31 7.3 Power Off Sequence........................31 7.4 Continue after Safety Break......................31 8. Prepare for a Job............................. 33 8.1 Introduction............................
  • Page 4 Kongsberg V-series 11.1 Introduction............................ 51 11.2 Adjust Active Tool...........................51 11.3 Tool Height Calibration........................52 11.4 Lag Settings (for Rotating Tools)....................52 11.5 Rotation Adjustment (for Rotating tools)..................54 11.6 Center Offset Adjustment......................55 11.7 Manual adjustment of Center Offset and angle................. 56 11.8 Tool Offset............................
  • Page 5 Contents 13. Tool inserts............................. 93 13.1 Ball Point Pen..........................93 13.2 Bevel Knife............................94 13.3 Bevel Knife U20..........................95 13.4 Braille Tool............................95 13.5 CorruSpeed Knife......................... 100 13.5.1 Tool adjustment......................... 101 13.6 Crease Tool........................... 102 13.6.1 Tool adjustment......................... 102 13.7 Crease Tool, 60 mm........................103 13.7.1 Tool adjustment.........................
  • Page 6 15.6 Chiller2016 Fuse replacement....................133 16. Vacuum Cleaner..........................135 16.1 Vacuum Cleaner, Zefiro....................... 135 16.1.1 How to use......................... 135 16.2 Vacuum Cleaner, High-capacity, TB ESKO.................. 137 16.2.1 How to use......................... 137 16.3 Compact Vacuum Cleaner......................139 16.3.1 How to use......................... 139 17.

  • 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 V-series 2. Change Record Description Date dd-mm-yy 20-05-2016 jhbe Document is updated according to iPC ver 2.0 06-09-2016 jhbe The importance of MultiCUT chuck cleaning is emphasized 18-10-2016 jhbe CorruSpeed information updated 24-10-2016 jhbe MultiCUT-HP, new chiller and information...

  • Page 9: Welcome

    Kongsberg V-series 3. Welcome Welcome to the User Manual for Kongsberg V-series running iPC 2.0. This manual will provide a complete and detailed description of Cutting Table functions. There is a separate user manual for i-cut Production Console (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.

  • Page 10: Using This Manual

    Kongsberg V-series 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 V-series Appendices • Vacuum Cleaner - basic information. • - 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. Start button The italic style indicates this is a button on the Operator panel.

  • Page 12: Local Languages

    Kongsberg V-series 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: Safety Regulations

    Kongsberg V-series 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.

  • Page 14: Requirements To Be Met By Operators

    • Utilizing accessories other than those specified by Esko. 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...

  • Page 15: Danger Zones

    Kongsberg V-series 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: Loose Clothing

    Kongsberg V-series 5.5.3 Loose Clothing While working with this machine, do not: • 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.

  • Page 17: I-Camera Strobing Light

    Kongsberg V-series • Eye Protection should be used by any personnel working with MultiCUT. 5.5.6 i-Camera strobing light If your system includes i-Camera, please read this warning carefully: WARNING i-Camera is equipped with LED strobing light. The LED default frequency (10 Hz) is in a range that can cause photosensitive epileptic reactions amongst susceptible people.
  • Page 18 Kongsberg V-series Do not Touch Potential areas with a risk of being squeezed are marked with the Do Not Touch sign. These areas are: • Between Y carriage and rack • Between the table top and the moving traverse. • Underneath the tool head.

  • Page 19: Safety Devices

    Kongsberg V-series 5.7 Safety devices 5.7.1 Overview Device no Description Main Power Switch Emergency Stop Button Warning Lamp / Status Lamp Photo cell supervision, Dynaguard Traverse Stop Switches, Dynaguard 5.7.2 Emergency Stop Button Switch positions: - Emergency Stop is switched OFF.  ...

  • Page 20: Warning Lamp On Top Of Y Carriage

    Kongsberg V-series 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. 5.7.3 Warning Lamp on top of Y Carriage...

  • Page 21: 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 22 Kongsberg V-series Beneath 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.
  • Page 23 Kongsberg V-series The DynaGuard Safety System photo cell beam c will stop the 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.

  • Page 24: System Description

    Kongsberg V-series 6. System Description 6.1 Naming conventions V-series 1 Table top 6 Main Power on/off switch 2 Y carriage 7 Operator Panel 3 Traverse 8 Emergency Stop button 4 Tools 9 Traverse Safety Stop switches (DynaGuard) 5 Main Power Unit (MPU)

  • Page 25: Main Power Switch

    Kongsberg V-series Y - Y-axis X2 - X2 end of traverse Z - Z axis The arrows indicates positive moving direction. 6.2 Main Power Switch Switch positions: - the Main Power to the machine is switched OFF. - the Main Power to the machine is switched ON.
  • Page 26 Kongsberg V-series Press this button to Start 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.

  • Page 27: Variable Blow Back

    Kongsberg V-series The size of the incremental movement can be changed from Machine Configuration->Setup. Tool Down Press the Tool Down button to manually operate the machine with a tool in the down position. Cancel by pressing Tool Down a second time.

  • Page 28: Pressurized Air System

    Kongsberg V-series 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...
  • Page 29 Kongsberg V-series SysLoad Program for download of updates to CU–modules. HWT800 Hardware test program, see separate HWT800 User Manual.

  • Page 30: Basic Operations

    Kongsberg V-series 7. 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 31: Reset Safety System

    Kongsberg V-series 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. 7.2 Reset Safety System Press Pause to Reset Safety System.
  • Page 32 Kongsberg V-series Reset the Safety System by pressing the Pause pushbutton. The Warning Lamp on top of the Y carriage should be on without flashing. Observe that Servo Power is switched on, Press Start to continue.

  • Page 33: Prepare For A Job

    Kongsberg V-series 8. Prepare for a Job 8.1 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 34: Production Setup

    Kongsberg V-series 8.4 Production Setup Opened Job->Production Setup. Verify correct Production Setup: • Number of Copies • Accuracy/Speed Prioritization • Select Reference Point and Job Position • Step and Repeat • Registration • Material Handling • Tool Head Parking 8.5 Speed Setting Opened Job->Production Setup->Quality.

  • Page 35: Job Execution

    Kongsberg V-series Proper selection is important to achieve the best possible material hold down. 8.8 Job Execution Before execution, check this: Verify that Opened Job is ready for production. Verify that the Table View display of the Job is reasonable.

  • Page 36: Make A Pen Plot

    Kongsberg V-series Ensure the vacuum cleaner container is prepared for the actual job. Empty the container regularly. Note: Milling Jobs should be executed in High Quality mode. 8.10 Make a Pen Plot Follow the procedure for how to prepare for and execute a job.
  • Page 37 Kongsberg V-series Menu Bar->Machine->Adjust Tool Height Machine Panel Toolbar->Tool Height • A wizard dialog appears. • Follow the instructions in the wizard to complete calibration. Measure all tools, started from Operators panel, procedure • Press the Pause button for more than 2 sec.
  • Page 38 Kongsberg V-series • Press the Measure Tool button.   • A wizard dialog appears.   • Follow the instructions in the wizard to complete calibration.   • Height Settings Current setting: The automatically measured height value.   • Automatic Measurement Adjustment New offset setting:...
  • Page 39 Kongsberg V-series All Measuring Pad operations are cancelled by: • Press Close in the active dialog. • Press Pause on Operators Panel...

  • Page 40: How To Procedures, Advanced

    Kongsberg V-series 9. How To Procedures, Advanced 9.1 Cutting Thick Materials When preparing materials with thickness between 45 – 50 mm (1¾ - 2 in.), the following rules apply: • No Camera operations are available. • Disable Measure Material Thickness.

  • Page 41: Multi Pass Milling

    Kongsberg V-series 9.3 Multi Pass Milling Opened Job->Layers->Edit Layer Menu Bar->Layer->Edit Layer 1. pass 2. pass 3. pass - mill through and clean 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.

  • Page 42: Work With Different Reference Point Settings

    Kongsberg V-series This function requires that the table 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...

  • Page 43: System Setup

    Kongsberg V-series 10. System Setup 10.1 Introduction This chapter will explain functions and parameters that are important for the V- system to run properly. It is a supplement to the information available from the User Manual for i-cut Production Console.

  • Page 44: Adjust X1 To X2 Angle

    Kongsberg V-series Board Size 10.2 Adjust X1 to X2 Angle Machine Connection->Machine Configuration->Installation_>Adjust X1 to X2 Angle Use this wizard to obtain correct angle between X axis and Y axis. Typical use is after maintenance or repair. Procedure: 1. Execute the Adjust X1 to X2 Angle function.

  • Page 45: Set Main Reference Point

    Kongsberg V-series Follow instructions from the wizard. If your table is equipped with Rulers, please complete the wizard for left and right ruler. For the table to operate properly an exact registration of the Ruler Positions is necessary. This is a one time job, but it can be necessary to repeat the procedure if mechanical maintenance has been carried out on the table or traverse.

  • Page 46: Reference Points And Coordinate System

    Kongsberg V-series It is recommended to execute this function if the Cutting Mat is worn out and after the Cutting Mat has been replaced.   Procedure: 1. If the table is equipped with a Conveyor Belt, move the belt junction away from the table surface.
  • Page 47 Kongsberg V-series The Main Reference Point position The Main Reference Point is a fixed position on the Cutting Table marked as a cross of drilled holes. The User Defined Reference Points are all specified relative to the Main Reference Point. Thus, moving the Main Reference Point will move these reference points as well.

  • Page 48: Table Speed

    Kongsberg V-series Rulers and Reference Points The Ruler System ensures an easy and correct positioning of the material on the table. The Main Reference Point shall be defined dr = 10 mm/0.39 in. inside the ruler. When you use the Right Ruler, the Reference...

  • Page 49: Jog Settings

    Kongsberg V-series Modify 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.

  • Page 50: Router Setup

    Kongsberg V-series • 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.

  • Page 51: Tool Configuration And Adjustment

    Kongsberg V-series 11. Tool Configuration and Adjustment 11.1 Introduction Machine Connection->Tool Configuration The Tool Configuration dialog is used for all tool settings and adjustments. 11.2 Adjust Active Tool From the Adjust Selected Tool – dialog, all Tool Adjustment Wizards are executed.

  • Page 52: Tool Height Calibration

    Kongsberg V-series We recommend using a sheet of Folding Carton material, 5-6 mm / 0.2 inch, when executing the adjustments. Note: All tools need to be adjusted in the position they will be used. Before any adjustment, complete a Table Top Reference function: Menu Bar->Machine->Set Table Top Reference...
  • Page 53 Kongsberg V-series 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 54: Rotation Adjustment (For Rotating Tools)

    Kongsberg V-series 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. 11.5 Rotation Adjustment (for Rotating tools) Optimal Angular Offset may vary with different material strength and thickness.

  • Page 55: Center Offset Adjustment

    Kongsberg V-series 10.Note how the knife enters into the material. 11.Press Tool Override Down once more to lift the Tool again. 12.If knife enters exact into the cut, the angle is correct; select Finish to exit. 13.If seen in the cutting direction, the knife enters to the left of the cut, the Angular Offset Value should be decreased.

  • Page 56: Manual Adjustment Of Center Offset And Angle

    Kongsberg V-series 10.Press Tool Override Down once more to lower the Tool, and Jog the same distance back. 11.Press Tool Override Down once more to lift the Tool. 12.The two cuts should follow exactly the same path. 13.If exact, the Center Offset is correct, select Finish to exit.

  • Page 57: Maintain Tool List (More

    Kongsberg V-series The Laser Pointer is the reference: 1. Place an appropriate test material on the table, and switch Vacuum On. 2. Select the Tool to be adjusted. 3. Press Adjust Active Tool to enter the Wizard Selection Dialog. 4. Select Offset Adjustment.
  • Page 58 Kongsberg V-series • Add new Tools • Add tools that fails during Automatic Tool Detection The Tool is added to the Tool List.

  • Page 59: Tooling System

    Kongsberg V-series 12. 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.

  • Page 60: Tool Heads Available, Overview

    Kongsberg V-series Motor cable and connector When disconnecting the motor cable, use the plug. 12.3 Tool Heads available, overview FlexiHead FlexiHead is a Multi-purpose Tool Head prepared for the following tools: Bevel Knife KissCut Knife Psaligraphy Knife Crease Tool Knife Tool...

  • Page 61: Tool Head Mount / Dismount

    Kongsberg V-series 12.4 Tool Head mount / dismount >> >> Be careful not to apply too much force when fixing the signal cables. 12.5 FlexiHead...
  • Page 62 Kongsberg V-series Tool Head Description 1. Tool positions 1, 2, 3 with locking knobs 2. Outlet for Reciprocating Knife motor 3. Laser pointer 4. Measuring foot / material hold down foot. Has 3 functions: a. Measure the thickness of the material on the table b.

  • Page 63: Multicut

    Kongsberg V-series Tool Rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset to Laser Pointer. 12.6 MultiCUT 12.6.1 Introduction MultiCut MultiCUT is a special purpose tool head, which can be equipped as follows: •...

  • Page 64: Tool Head Description

    Kongsberg V-series MultiCUT chucks Different chucks are available for the HF-45 spindle. Be aware that the chucks for HF-45 and HF-62 are different and they cannot interchange. Replacing a chuck Replacing a chuck is described in the User Manual for the machine.
  • Page 65 Kongsberg V-series MultiCUT   1. Tool position 1 (FlexiHead tool insert) 2. Tool position 2 (FlexiHead tool insert) 3. Laser pointer 4. Tool position 3 5. Measuring foot / material hold down foot 6. Electrical connection, router spindle motor 7. Electrical connection, reciprocating motor 8.

  • Page 66: Safety Issues

    Kongsberg V-series 1. Router bit. Shaft diameter is 6 mm. 2. Chuck. MultiCUT is equipped with one 6 mm chuck on delivery. 3. Spindle When MultiCUT is not in use, the suction tube is fixed to the traverse as shown here.
  • Page 67 Kongsberg V-series • Follow the Vacuum Cleaner filling level carefully. • Empty the container before the level reach the inlet position (indicated in red). Suction House Always, when executing a job, let the Suction House float on top of the material.

  • Page 68: Precautions

    Kongsberg V-series Clean surface Keep the table and material surface clean, free from obstacles. 12.6.4 Precautions Spindle motor power consumption supervision Machine Panel->Spindle Power The MultiCUT-HP spindle is prepared for continuous operation between 0 – 100 % Watt. A power load of 70-80% will allow good working conditions for the Spindle Motor.
  • Page 69 Kongsberg V-series Chuck Open/Close valve operation Never operate the Chuck Open/Close valve while the 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.
  • Page 70 Kongsberg V-series Long term storage More than 4 weeks storage of a spindle or a MultiCUT/MultiCUT-HP requires: 1. Turn the spindle by hand about 20 turn every 4 weeks. 2. Spindle must be stored horizontally. Consider having a replacement spindle...

  • Page 71: Routing Advice

    Kongsberg V-series Empty vacuum cleaner 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. 12.6.5 Routing Advice Milling bits For thin materials, use bits with short cutting...
  • Page 72 Kongsberg V-series For best performance and minimum wear, do not let the bit stick out more than necessary . Never use higher RPM than recommended by the bit supplier. Special care should be taken when using bits with cutting diameter larger than shank diameter.
  • Page 73 Kongsberg V-series Acrylic or Multi Purpose bits 1. Acrylic Bits (A) are polished, extra sharp for acrylic, wood etc. 2. Multi Purpose Bits (MP) have a higher wear resistance, and are suitable for aluface, plastics, MDF, plywood, wood etc. Multi Purpose Bits can be identified by a small tooth at the tip (left hand bit on the picture).

  • Page 74: Bits And Bit Change

    Kongsberg V-series 2. Cover unused table area to increase Vacuum Hold Down Level. 3. Use Wash-Out functions instead of creating small waste parts. Using other tools in combination with the MultiCUT-HP It might be necessary to reduce the acceleration in order to achieve an optimal Cutting Quality when combining a heavy tool head with high quality cutting tools.
  • Page 75 Kongsberg V-series Only the round part of the shaft should be inside the Chuck. See the Bit Length and Position on page 80 – chapter for more information.  Release the Lock to allow the Suction House moving down to its down position.

  • Page 76: Chuck Change And Cleaning

    Kongsberg V-series Sleeve Adjustment Tools are available in two versions, with different depths. Use the Sleeve Adjustment Tool in order to: • Ensure correct insertion of milling bit. • Ensure equal bit height when replacing a milling bit. Additional tool height adjustment not necessary.
  • Page 77 Kongsberg V-series Follow the procedure strictly.   Normally, the chuck has a long lifetime. Extended vibrations or impacts may hurt the chuck, and cause bad milling results. Trying a new chuck is the easiest way to identify if the chuck is the problem.
  • Page 78 Kongsberg V-series Hold the rotor with the 17 mm key and unscrew the chuck using the Chuck Tool. If the bit is stuck, hold the rotor with the 17 mm key and unscrew with a 12 mm key. Note: Tool Open must be pressurized.
  • Page 79 Kongsberg V-series 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. Apply small quantities of grease to the threads of the chuck, and to the outer cone and cylindric surface of the chuck (green arrows).

  • Page 80: Bit Slipping, Chuck Change

    2. Bit vibrations. When replacing the chuck, follow instructions in Chuck Change and Clean. New chucks are available from Esko store. 12.6.9 Bit Length and Position Keep distance d small. For best performance and minimum wear, do not let the bit stick out more than necessary.

  • Page 81: False Air Valve

    Kongsberg V-series 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 with balanced surface should have a clamping length f of min. 20 mm/0.8 inches.

  • Page 82: Table Top And Height Adjustment

    Kongsberg V-series 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 adjusted, the router bit should barely touch the top surface of the material.    ...

  • Page 83: Miscellaneous

    Kongsberg V-series Milling underlay (U) on top of the cutting underlay: To be able to mill through the material, the thickness of the milling underlay must be > 2 mm / 0.08 inch. If the thickness of the milling underlay (U) is <...

  • Page 84: Chiller 1 For Multicut-Hp

    Kongsberg V-series Vacuum clean the milling underlay The Vacuum Cleaner can be used for automatic cleaning of the felt mat: Prepare program to make a file that covers the actual area. Set “bit size” to 65 mm (2.5 inch). Hint: •...

  • Page 85: Chiller, Error Conditions

    Kongsberg V-series Flow Measurement During operation, check the water flow level displayed on the chiller meter. For proper operation, the flow level should be > 1,0 l/min.   12.7.2 Chiller, Error Conditions One common error signal is routed from the Chiller system to the inverter and further into the control system.

  • Page 86: Chiller Heater, Operation

    Kongsberg V-series 12.7.3 Chiller Heater, Operation Notes: 1. The Chiller Heater is optional. 2. The Chiller Heater must be filled with water before connecting mains. 3. The Chiller Heater is correctly configured when shipped from the factory. Normally, there is no need for modifications.

  • Page 87: Chiller2016 For Multicut-Hp

    Kongsberg V-series Programs available Program Temperature range Temperature range Hysteresis from ( to ( Frost protection Factory Setting Correct factory setting is Program = 5 and temperature = 26 oC (Chiller with heater). 12.8 Chiller2016 for MultiCUT-HP 12.8.1 Introduction Specifications...

  • Page 88: Startup

    Kongsberg V-series 12.8.2 Startup Ensure the following pre-requisites are in place for correct startup: • Note: Never start the chiller without liquid. • Signal cable (to inverter) is connected to the chiller unit. • Chiller fluid level should be MAX. If not, fill with fresh water.

  • Page 89: Measuring Foot

    Kongsberg V-series   During normal operation, the cooling medium temperature is displayed.   If any chiller failure occurs: • Alarm signal is generated. • Chiller will stop. • Look at the chiller display to see the real reason for the problem:...

  • Page 90: Laser Pointer

    Kongsberg V-series Note: In Q1/2017, the strong springs used earlier were replaced by a set of softer springs, in order to avoid the foot scratching the material surface. If needed, a set of strong springs, together with a replacement procedure, is available in the tool kit included in the shipment.

  • Page 91: X-Pad

    Kongsberg V-series 12.11 X-Pad 12.11.1 X-Pad Calibration Note: Remove any cup or cover surrounding the tool tip during this procedure. As a consequence, take care.   In order to work properly, the X-Pad itself must be calibrated. The following tools are applicable when the calibration procedure is carried out: •...

  • Page 92: Tool Depth And X-Pad

    Kongsberg V-series 12.11.2 Tool Depth and X-Pad Be aware how X-Pad is working; it is the tool tip that is measured. Depending upon the actual tool, it might be necessary to add depth in order to achieve cut or drill hole through the material.

  • Page 93: Tool Inserts

    Kongsberg V-series 13. Tool inserts Knife Blades are extremely sharp. Take care when handling Knife Tools. 13.1 Ball Point Pen The Ball Point Pen tool is available for pen drawing. Tool pressure is adjustable by a knob on top of the tool.

  • Page 94: Bevel Knife

    Kongsberg V-series Parameter Description Tool Offset Adjust offset relative to laser pointer. For more information about how to run the adjustment wizards, see Tool Configuration. 13.2 Bevel Knife Bevel Knife is a special-purpose tool for 45 degree angled cuts. Lag = 3.5 mm / 0.14 in.

  • Page 95: Bevel Knife U20

    Kongsberg V-series About tool adjustment For the Bevel Knife, we recommend the manual procedures for tool rotation and centre offset adjustment.   Use a thin Folding Carton material when adjusting tool rotation and centre offset.   Remember that you should look at the bottom side of the material for correct alignment.  ...
  • Page 96 Kongsberg V-series 1. Keep the tool in upright position during this process. 2. Remove the cap and the plunger. 3. Pour spheres into the tool. 4. Insert the plunger and the cap. Shake the tool lightly. 5. Push the dispensing mechanism up.
  • Page 97 Kongsberg V-series The supplied milling bit is heavily unbalanced and should not be run faster than 20.000 RPM to avoid excessive wear to the milling spindle! This also means that you should not use this bit when warming up the milling spindle as the warm up sequence exceeds 20.000rpm.
  • Page 98 Kongsberg V-series Configure Tool Menu Bar->Advanced->Configure Tools... Braille Tool should be defined with the following parameters enabled: • Velocity Z (max speed) • Z-axis Depth (0) • Drill holes (on) Preparing Layers for Braille Tool Opened Job->Layers->Edit Layers When making braille signage, you need two identical Layers with the braille pattern, one for milling holes and one for inserting braille spheres.
  • Page 99 Kongsberg V-series According to the Raster Braille manual the hole depth should be 1,07mm (0,042”). You may find that the holes being milled are either too shallow or too deep. If so, use this parameter to adjust to a suitable setting.  ...

  • Page 100: Corruspeed Knife

    Kongsberg V-series Select a font size, which gives correct distance between the dots/patterns. Details are found in the Raster Braille manual. As with other fonts, outlines of the text need to be created before creating the output file for i-cut Vision.

  • Page 101: Tool Adjustment

    Kongsberg V-series Material crushing depends upon two adjustments: A - Knife tip exposed Adjust until the distance d is 1.0 mm/0.04 in. less than material thickness. One turn (CW) on A increase d with 1 mm/0.04 in. B - Foot pressure Adjust foot pressure.

  • Page 102: Crease Tool

    Kongsberg V-series Parameter Description 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.

  • Page 103: Crease Tool, 60 Mm

    Kongsberg V-series 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.

  • Page 104: Tool Adjustment

    Kongsberg V-series 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.

  • Page 105: Reboard Drill Tool

    Kongsberg V-series 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. 13.8.2 Reboard Drill Tool Reboard Drill Tool is a tool insert for a standard XL tool position.

  • Page 106: Drill Bit Dimensions

    Kongsberg V-series 13.8.3 Drill Bit dimensions This figure shows the drill bit requirements for the tool to operate properly. 13.8.4 Tool Adjustment For this tool, complete the following adjustments: Parameter Description Tool Height The tool tip should touch the material surface.

  • Page 107: Foam Knife

    Kongsberg V-series 13.9 Foam Knife The Foam Knife tool for FlexiHead is a special purpose tool for cutting foam materials up till 1" (25 mm). The tool is available for all tables with raised traverse. Note: • As the Foam Knife is longer than the other tools in the Tool Head, it is not possible to run the Foam Knife tool in combination with other tools in the Tool Head.

  • Page 108: Liquid Ink Tool

    Kongsberg V-series 13.10.1 Liquid Ink Tool Liquid Ink Tool is for ink drawing on foil. The tool is prepared for Staedtler 727HPK35-9 insert. Ink tool assembly 13.10.2 Fibertip Tool Fibertip Tool is for ink drawing. The tool is prepared for Staedtler Lumocolor...

  • Page 109: Tool Adjustment

    Kongsberg V-series Fibertip tool assembly 13.10.3 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.
  • Page 110 Kongsberg V-series Description A complete KissCut tool consist of: A - The tool body with knife adapter B - Pressure unit no x (two models available) C - Locking knob D - Knife Blade E - Knife foot F - Spanner Replace Knife Blade This figure shows how the Knife Blade is fixed...
  • Page 111 Kongsberg V-series Tool pressure Knife pressure is adjusted by turning the If higher knife pressure is needed, interchange Pressure Adjustment knob available on top Pressure units. of the KissCut tool. Pressure range: Adjust and make a test cut to obtain correct Pressure unit #1: 0,3 - 3,5 N setting.

  • Page 112: Microcut

    Kongsberg V-series 13.12 MicroCut The MicroCut tool is a special purpose knife tool for applications where exact cutting depth is required. 1 – Foot, floating on top of the material 2 – Foot pressure adjustment 3 – Depth meter. For details, see (218).

  • Page 113: Psaligraphy Knife

    Kongsberg V-series 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.

  • Page 114: Tool Adjustment

    Kongsberg V-series 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 13.13.1 Tool adjustment For this tool, complete the following adjustments:...

  • Page 115: Rbi 90-16 (Rigid Board Insert)

    Kongsberg V-series 13.14 RBI 90-16 (Rigid Board Insert) Insert / remove Knife Blade Use Allen Key, 3 mm, to fix / loosen the Knife Ensure the blade is correctly aligned. Blade. After a blade change, the tool depth should be checked again.

  • Page 116: Reciprocating Knife

    Kongsberg V-series 13.15 Reciprocating Knife 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.

  • Page 117: Tool Adjustment

    Kongsberg V-series Replace Knife Blade Pull out the electrical connection. Note: Pull using the connector, not just the cable. Remove the foot by pulling the foot straight out. Loosen the screw A and replace the knife. Ensure the knife has correct position relative to the screw.

  • Page 118: Rigid Material Knife

    Kongsberg V-series 13.16 Rigid Material Knife Insert / remove knife blade Use a 3 mm Allen Key to fix / loosen the knife Ensure the blade is correctly aligned. blade. After a blade change, the tool depth should be checked again.

  • Page 119: Rotacut

    Kongsberg V-series 13.17 RotaCut RotaCut is a special tool for cutting light materials, as thin fabric. Maximum cutting depth is 2 mm / 0.07 inch. Note: Due to the characteristics of this knife tool, some restrictions apply to the use of it: •...
  • Page 120 Kongsberg V-series 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 Configuration. For more information about how to run the adjustment wizards, see...
  • Page 121 Kongsberg V-series Push the foot into position. A self-locking mechanism ensures the foot is kept in place. Note: Be careful not to hit the sharp knife. Layer Setup for RotaCut Correct setting of Lag- and Width - values are shown.

  • Page 122: Static Knife

    Kongsberg V-series 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 123: Tool Adjustment

    Kongsberg V-series Knife direction The locking screw will always point towards the The locking screw will always point towards the cutting direction cutting direction 13.18.1 Tool adjustment For this tool, complete the following adjustments: Parameter Description Tool Height The tool tip should touch the material surface.

  • Page 124: Vixx Knife Tool, Mounting/Adjustment

    Kongsberg V-series 13.19.1 VIxx Knife Tool, Mounting/Adjustment Remove the knife adapter from the tool and Position the tool adapter onto the shaft. insert the upper part into the tool position. Observe Alignment Pin orientation. Keep the knife adapter in this position while you turn the tool shaft…...

  • Page 125: Vi45 Knife Tool

    Kongsberg V-series After a blade change, the tool depth should be checked again. About tool adjustment For the VIxx Knife Tool, we recommend the manual procedures for tool rotation and centre offset adjustment.   Use a thin Folding Carton material when adjusting tool rotation and centre offset.  ...
  • Page 126 Kongsberg V-series Remove the knife adapter from the tool and Position the tool adapter onto the shaft. insert the upper part into the tool position. Observe Alignment Pin orientation. Keep the knife adapter in this position while you turn the tool shaft…...

  • Page 127: Vi45-10/12 Knife Tool

    Kongsberg V-series 13.21 VI45-10/12 Knife Tool A – knife adapter Lag = 0mm. 13.21.1 VIxx Knife Tool, Mounting/Adjustment Remove the knife adapter from the tool and Position the tool adapter onto the shaft. insert the upper part into the tool position.
  • Page 128 Kongsberg V-series …in order to lock the tool adapter in its position. How to set the cutting depth of the VIxx Knife Tool The default cutting depth is to cut through the entire material.   Define the depth of the bevel cut in the Layer Setup.

  • Page 129: Maintenance

    Kongsberg V-series 14. Maintenance More information about maintenance is available in the Maintenance Manual. Warning Main Power should be switched off before cleaning is carried out. 14.1 Daily maintenance • Inspect the equipment in order to prevent any irregularities. • The table surface should be kept clean at all times.

  • Page 130: Fuse Replacement

    Kongsberg V-series 15. 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 15.1 MPU fuses MPU Location Note: MPU location is model dependent.

  • Page 131: X1 Fuses

    Kongsberg V-series Fuse Details Fuse location 115V 230V F1 and F2, line fuses T 10A 250V (5x20 mm) T 5A 250V (5x20 mm) F24, +24V fuse T 6,3A 250V (5x20 mm) T 6,3A 250V (5x20 mm) F48, 48V Servo power fuse...

  • Page 132: Y/Z Fuses

    Kongsberg V-series Fuse Location 1 – 6/12A amplifier X2. Procedure 1. Remove X2 cover. 2. Check the X2 fuse with ohm - meter. If blown, replace with a new, identical fuse. 3. Replace covers. 4. Insert main power cable into the wall socket and turn main power ON.

  • Page 133: Tool Rotation/Reciprocating Knife Fuses

    Kongsberg V-series Procedure 1. Remove Y cover. 2. Check the Y and Z 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.
  • Page 134 Kongsberg V-series 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)

  • Page 135: Vacuum Cleaner

    Kongsberg V-series 16. Vacuum Cleaner 16.1 Vacuum Cleaner, Zefiro 16.1.1 How to use Filter Shaking 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.
  • Page 136 Kongsberg V-series Note: You can use the 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...

  • Page 137: Vacuum Cleaner, High-Capacity, Tb Esko

    Container with Plastic Bag ready for operation Detailed information about how to operate the Vacuum Cleaner is available in the Zefiro 75 Operators and maintenance manual. 16.2 Vacuum Cleaner, High-capacity, TB ESKO 16.2.1 How to use Introduction 1 – Filter Chamber 2 –...
  • Page 138 Kongsberg V-series Filter Shaking 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.

  • Page 139: Compact Vacuum Cleaner

    Kongsberg V-series Fix the Plastic Bag to the steel bar. Shake the filter well before emptying the container. 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.
  • Page 140 Kongsberg V-series 1. Suction tube inlet 2. Container fixture 3. Filter unit locking mechanism 4. Motor 5. Filter unit How to empty container 1. Ensure vacuum cleaner motor is off. 2. Remove the suction tube (1). 3. Release the container (3).

  • Page 141: Install Software

    Kongsberg V-series 17. Install Software For information about software installation, see the Installation Manual for the actual machine. Available on the Documentation DVD.

  • Page 142: 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 143: Ipc

    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 144 Kongsberg V-series 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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