Page 1 Kongsberg XP User Manual 10 - 2020 | XP...
Page 2: Table Of Contents
Kongsberg XP Contents 1. Preface................................8 2. Change Record...............................9 3. Introduction..............................11 3.1. Welcome............................... 11 3.2. FCC conformity statement........................11 4. Using this manual............................12 4.1. Main Sections............................12 4.2. Name Styles and Symbols........................13 4.3. Pictures and Illustrations........................13 4.4. Local Languages..........................14 5.
Page 3 Contents 5.11. Residual risks............................. 27 6. System Description............................. 30 6.1. Naming Conventions........................... 30 6.2. Main Power Switch..........................31 6.3. Operators Panel........................... 31 6.4. High Pressure Air System........................33 6.5. Application Programs Available......................34 7. Basic Operations............................35 7.1. Introduction............................35 7.2.
Page 4 Kongsberg XP 10.4. Adjust Measuring Station Position....................54 10.5. Set Ruler Position..........................54 10.6. Set Main Reference Point........................54 10.7. Map Table Top Surface........................55 10.8. Calibrate Foot on Measuring Station....................56 10.9. Reference Points and Coordinate System..................56 10.10. Table Speed............................. 58 10.11.
Page 5 Contents 12.8. Dual HDU - Dual Heavy Duty Unit.......................94 12.8.1. Dual HDU HD Perf Position.......................96 12.8.2. New mounting procedure for HD insert tools................98 12.9. VariAngle unit...........................100 12.9.1. Introduction..........................100 12.9.2. Safety precautions........................ 100 12.9.3. Tool description........................101 12.9.4. Description of knife blade adapters..................102 12.9.5.
Page 6 Kongsberg XP 12.19. Braille Tool............................155 12.20. CorruSpeed Knife........................... 159 12.20.1. Tool adjustment........................161 12.21. Braille Tool............................161 12.22. Drill / Pen Tool..........................166 12.23. Drill Tool............................168 12.24. Ballpoint Pen..........................169 12.25. Measuring Foot..........................170 12.26. Laser Pointer..........................170 13. Maintenance............................... 171 13.1.
Page 7 19. MRF Weight list............................207 20. Vacuum Cleaner............................208 20.1. Vacuum Cleaner, Zeﬁro........................208 20.1.1. How to use..........................208 20.2. Vacuum Cleaner, High-capacity, TB ESKO..................210 20.2.1. How to use..........................210 20.3. Compact Vacuum Cleaner....................... 213 20.3.1. How to use..........................213 21. Install Software............................215 22.
Page 8: Preface
This copyright does not indicate that this work has been published. This material, information and instructions for use contained herein are the property of Esko-Graphics Kongsberg AS. There are no warranties granted or extended by this document. Furthermore, Esko-Graphics 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.
Page 9: Change Record
Kongsberg XP 2. Change Record Description Date dd-mm-yy 03-02-2017 jhbe TakeUp Unit, information added 18-04-2017 jhbe Measuring station operation, information added. 20-04-2017 jhbe Braille tool description added 20-04-2017 jhbe Bevel 45 tool adapter description added 03-07-2017 jhbe Tool Insert Position, limitation information added.
Page 10 Kongsberg XP Description Date dd-mm-yy 02.04.2020 Safety section updated 08.06.20 FCC conformity statement added 14.09.2020 Minor update 22.09.2020 Warning sign "Sharp knives" added 27.10.2020 VariAngle unit included...
Page 11: Introduction
3. Introduction 3.1. Welcome Welcome to the User Manual for Kongsberg XP running iPC. This manual will provide a complete and detailed description of all 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 12: Using This Manual
Kongsberg XP 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 13: Name Styles And Symbols
Kongsberg XP Tooling System • Tool descriptions. Maintenance • This chapter describes maintenance to be carried out by the customer. Fuse Replacement • Fuse location and speciﬁcation. Appendices • Roll Feeder - basic information. • Vacuum Cleaner - basic information.
Page 14: Local Languages
Kongsberg XP 4.4. Local Languages This manual is available in a wide range of local languages. Screen pictures and illustrations remain in English language. For safety related illustrations, text is translated.
Page 15: Safety Regulations
Kongsberg XP 5. Safety Regulations 5.1. Introduction The XP table is designed to conform to Safety Regulation standards. Dangers are designed away as far as practically possible. Nevertheless, all hazards could not be removed. This section must be read carefully to understand the remaining risks, warning symbols, responsibilities, requirements and safety precautions.
Page 16: The Operators
Have read and understood the instructions described in safety regulation as well as any other safety warnings. Training will be given to operator(s) nominated by the customer by the Esko service engineer as part of the system installation. The training covers: •...
Page 17: Definition Of Use
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. Warning sign explanation High voltage warnings • Main Power Unit (MPU) and vacuum pump Do not open cover on either MPU or vacuum pump before mains is disconnected from cutting table and vacuum pump.
Page 18 Kongsberg XP • Chiller Do not open cover on chiller before mains is disconnected from cutting table. Note: Different instruction for Cxx and Xxx. • Vacuum cleaner Do not open cover on vacuum cleaner before mains is disconnected from cutting table.
Page 19 Kongsberg XP Sharp knives Potential risk of being cut by sharp knives. Moving Parts Potential areas with a risk of being hit by Moving Parts are marked with the Moving Parts sign. These areas are: • Both traverse ends. •...
Page 20: Attention Areas
Kongsberg XP Knife blades and milling bitsare extremely sharp. This symbol is used in documentation to indicate operations where there is risk of being injured. Additional warning signs are found in relevant sections. 5.6. Attention areas 5.6.1. Mains power disconnection The main power switch on the operator station is intended for daily power on/off To permanently disconnect mains power, e.g.
Page 21: Loose Clothing
Kongsberg XP 5.6.3. Loose clothing While working with this machine, do not wear clothes or jewelry that can entangle with moving parts of the machine: • Ties • Loose necklaces • Scarfs 5.6.4. Noise level Hearing protection should be used by any personnel exposed to the noise from the machine.
Page 22: I-Camera Strobing Light
Kongsberg XP The milling spindle does not stop instantly. Always ensure that the red lamp has stopped ﬂashing, and by visual inspection that the milling bit has come to a complete standstill before touching it. Note: Only specially trained operators are allowed to operate milling tools.
Page 23: Safety Devices
Kongsberg XP 5.7. Safety devices 5.7.1. Overview 5.7.2. Emergency stop button Emergency stop buttons. Switch positions - Normal operation enabled - Emergency stop active. Servo power to the machine is switched off...
Page 24: Yellow/Black Tape
Kongsberg XP 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 stopping distances of traverse, Y carriage and tool head. To Continue operation after emergency stop, proceed as follows 1.
Page 25: Dynaguard Safety System
Kongsberg XP 5.7.5. DynaGuard safety system The lower beam is at about 70 mm / 2.75 in. above the table top to allow materials of 50 mm / 2 in. thickness. It is possible, but very dangerous to reach under the beam and into the hazard zone.
Page 26: Milling Warning Lamp
5.8. Protective equipment For the operators, Esko recommends the following protective equipment: Close-ﬁtting clothes to avoid being caught by the beam or the tool head which can cause injuries.
Page 27: Procedures In Case Of Malfunctions
Kongsberg XP 5.9. Procedures in case of Malfunctions Trouble-shooting and repair shall be performed by authorized personnel only. Contact the Esko global support. 5.10. Check before operation Before operating the equipment, check the following: • Electrical cables without damage •...
Page 28 Kongsberg XP Y carriage The top of the Y carriage is un-protected in all four directions. Actions: • Do not access the table work area or approach the traverse while the machine is operating. Rear side of traverse DynaGuard safety system light beams will...
Page 29 Kongsberg XP It is possible to reach under the lower DynaGuard light beam into tool hazard areas. Intentionally doing this during machine operation is very dangerous and considered non-intended use. Touching the milling bit while rotating Stop time of the milling spindle is up to 4 seconds.
Page 30: System Description
Kongsberg XP 6. System Description 6.1. Naming Conventions Machine 1 Cutting Table 5 Main Power on/off switch 2 Tools 6 Operator Panel 3 Y carriage 7 Emergency Stop button 4 Traverse 8 Main Power Unit (MPU) Axes X - X-axis P1 - P1 Tool Position.
Page 31: Main Power Switch
Kongsberg XP X2 - X2 end of traverse 6.2. Main Power Switch The Main Power Switch is located on the Operator Station: Switch positions - Main Power to the machine is switched OFF. - Main Power to the machine is switched ON.
Page 32 Kongsberg XP Start 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 33: High Pressure Air System
Kongsberg XP Press the two arrows to move the tool head a large step. Press the single arrow to move the tool head a small step. The size of the incremental movement can be changed from Option-> System setup.
Page 34: Application Programs Available
Kongsberg XP Air Pressure Regulator settings The air pressure should be adjusted to minimum 6 bar (6 kg/cm2, 6*105 Pa). Recommended pressure level is 7 bar (7 kg/cm2, 7*105 Pa). Consequences of too low air pressure level: • Execution will stop.
Page 35: Basic Operations
Kongsberg XP 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 36: Reset Safety System
Kongsberg XP Safety System Reset the Safety System by pressing the Pause pushbutton. 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.
Page 37: Continue After Safety Break
Kongsberg XP 7.5. 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.
Page 38: Prepare For A Job
Kongsberg XP 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 39: Production Setup
Kongsberg XP 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 40: Job Execution
Kongsberg XP From the Vacuum Zone setup – dialog, conﬁgure a suitable vacuum area for the job. Select Vacuum Zones that corresponds to the outline of your material. Proper selection is important to achieve the best possible material hold down.
Page 41: Milling Production
Kongsberg XP Recommended tooling is described in Esko Tooling Guide. 8.10. Milling Production Milling Production without Registration Marks is straight forward following the procedure described in Prepare for a Job - chapter. Recommended tooling is described in Esko Tooling Guide.
Page 42: How To Procedures, Advanced
Kongsberg XP 9. How To Procedures, Advanced 9.1. Optimize vacuum effect To ensure a well functioning material hold down, reduce the unnecessary air ﬂow as much as needed: Close vacuum zones that are outside of the material: Machine Panel Toolbar -> Vacuum Zones, or use Intelligent vacuum control.
Page 43: Cutting Thick Materials
Kongsberg XP 9.2. 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. Disable the Depth Referenced from Top function.
Page 44: Multi-Pass
Kongsberg XP 9.4. Multi-pass Multi-pass is a method to do a job, normally a milling job, in steps, by dividing the thickness into a number of steps (passes). The method can also be used for other tools, like crease wheels, foam knives, V-notch and VariAngle unit.
Page 45 Kongsberg XP Menu Bar->Advanced->Conﬁgure Tools Menu Bar->Layer->Edit Layer... Opened Job->Layers Tab->Edit Layer Example below shows conﬁguration of Reverse Operation from Menu Bar->Advanced->Conﬁgure Tools Reverse Operation can also be controlled from a button in Layers Tab: Status 1: Selected tool does not currently allow reverse side operation. Can be conﬁgured in Conﬁgure Tools dialog.
Page 46: Reverse Operation By Left And Right Rulers
Kongsberg XP Tumble means that the material is ﬂipped over top-to-bottom. 9.5.1. Reverse Operation by Left and Right Rulers Workﬂow Step 1 - the sheet is aligned towards the Step 2 - the sheet ﬂipped and aligned towards the Left Ruler.
Page 47: Reverse Operation In Combination With Step And Repeat
Kongsberg XP Workﬂow Step 1 - Regmarks and corners are read by the Step 2 - the sheet is ﬂipped (turned or tumbled), Camera. and corners are read by the Camera. All other layers in the Job is processed. A current limitation of Reverse Operation with Camera is that all layers (except the regmark layer) must be processed from the reverse side.
Page 48: Work With Different Reference Point Settings
Kongsberg XP Reverse Operations in combination with Step and Repeat and Camera. For each copy deﬁned by Step and Repeat, you have to ﬂip the sheet and read Regmarks and corners. 9.6. Work with different Reference Point Settings Select the Reference Point to use from: Opened Job->Production Setup->Position->Reference Point...
Page 49 Kongsberg XP MZP Panel Each work zone is equipped with a panel that makes it possible to run the complete MultiZone Production sequence from the table. • 1 - Ready Lamp 2 - Ready Button • • 3 - Vacuum on Button •...
Page 50: Multizone, Workflow
Kongsberg XP 1680x3200 Work area 2210x3200 3210x1600 3210x3200 3210x4800 66x126 in mm/in 87x126 126.37x63 126.37x126 126.37x189 N/A Work area, MultiZone Production, 1680x1450 2210x1450 3210x1420 3210x2210 standard tabletop 66x57 87x57 126x56 126x87 mm/in 9.7.1. MultiZone, Workﬂow...
Page 51 Kongsberg XP - Attention Area. During operation in one zone, parts of the traverse will move into the other zone (photo cell beams, traverse end cover). To ensure a continous workﬂow, the operator should be very careful inside the Attention Area, not to trigger the safety system by his body or by material in and out.
Page 52: System Setup
Kongsberg XP 10. System Setup 10.1. Introduction This chapter will explain functions and parameters that are important for the XP system to run properly. It is a supplement to the information available from the User Manual for i-cut Production Console.
Page 53: Adjust X1 To X2 Angle
Kongsberg XP Set Table Acceleration Jog Settings Set Table Top Reference Conveyor Belt Control 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.
Page 54: Adjust Measuring Station Position
Kongsberg XP Procedure: 1. Execute the Register Table Size function. 2. Follow the instruction given by the wizard. 10.4. Adjust Measuring Station Position Machine Connection->Machine Conﬁguration->Installation_>Adjust Measuring Station Position Use this wizard to calibrate the position of the Measuring Station to the system. ...
Page 55: Map Table Top Surface
Kongsberg XP Use this wizard to establish the Main Reference Point (R). Typical use is after maintenance or repair, if the Main Reference Point has been accidentially moved. The Main Reference Point is a ﬁxed position on the Cutting Table marked as a cross of drilled holes.
Page 56: Calibrate Foot On Measuring Station
Kongsberg XP Note: iPC 2.1: The mechanism of compensating Z height during cutting, based on table top mapping, has been disabled when cutting underlay has been measured to be more than 5mm. This level is normally reached when milling on top of milling mat and conveyor belt.
Page 57 Kongsberg XP 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 58 Kongsberg XP Press the Set Panel Reference Point button on Operators Panel. The Panel Reference Point is set to current Laser Pointer Position Rulers and Reference Points The Ruler System ensures an easy and correct positioning of the material on the table.
Page 59: Jog Settings
Kongsberg XP Opened Job->Production Setup->Quality Here you specify if this is a High Quality Job or High Speed Job. 10.11. Table Acceleration Menu Bar->Advanced->Conﬁgure Tools...->Acceleration This is the default value for each tool when Layers are created. Note: Acceleration can be reduced to a % value of the maximum acceleration available.
Page 60: Set Table Top Reference
Kongsberg XP 10.13. Set Table Top Reference Menu Bar->Machine->Set Table Top Reference Follow instructions from the wizard. Machine Connection->Machine Conﬁguration->Installation_>Table Top Reference Follow instructions from the wizard. Machine Panel Toolbar->Table Top Reference Use this function to complete a Tool Height Reference calibration. ...
Page 61 Kongsberg XP This is a dialog where the Vacuum Zone Conﬁguration for the actual machine is speciﬁed. This setup is a one-time job as long as the Vacuum Zone Solution on the machine remains unchanged. The setup should correspond to the actual hardware. ...
Page 62: Milling Unit Setup
Kongsberg XP 10.15. Milling Unit Setup Machine Connection->Machine Conﬁguration->HW Conﬁguration->Milling Unit setup From the Milling Unit setup dialog, maintain the following parameters: Specify Milling unit If a milling unit is mounded, spedify milling unit type. If no milling unit is mounted, select None.
Page 63: Sheet Feed Correction
Kongsberg XP 10.16.2. Sheet Feed Correction If the Conveyor Belt feed length needs adjustment, use this function to adjust the movement of the Conveyor Belt to be shorter or longer. 10.17. Board Size Not implemented yet...
Page 64: Tool Configuration And Adjustment
Kongsberg XP 11. Tool Conﬁguration and Adjustment Machine Connection->Tool Conﬁguration The Tool Conﬁguration dialog is used for all tool settings and adjustments. Select tool and function. 11.1. Tool Conﬁguration The XP machine offers two different tool positions, P1 and P2, where different interchangeable tools can be mounted.
Page 65 Kongsberg XP P1 - P1 tool position, see table below C – Camera position P - Pen / Drill / Ink Tool holder position P2 - P2 tool position, see table below The following tool conﬁgurations are available: Tool Type...
Page 66: Tool Names
Kongsberg XP This table shows correct position for the different tools. The tool conﬁguration; the tools available depends upon the actual delivery. Notes: (1): An optional Tool Insert Position is required for these tools. (2): These units are permanently ﬁxed to the P1 tool position. ...
Page 67: Adjust Active Tool
Kongsberg XP 11.3. Adjust Active Tool Machine Connection->Tool conﬁguration->Adjust Active Tool Follow instructions from the wizard. From the Adjust Active Tool – dialog, all Tool Adjustment Wizards are executed. The following procedures are general descriptions of how to adjust the tools.
Page 68: Tool Height Calibration
Kongsberg XP Run this wizard to obtain correct Knife Lag value. Follow the instructions in the dialog. Add the measured value to the displayed value. Circle Lag Circle quality is determined by a parameter called Circle Lag. The parameter value will vary depending upon the actual material.
Page 69: Rotation Adjustment (For Rotating Tools)
Kongsberg XP 11.6. Rotation Adjustment (for Rotating tools) Optimal Angular Offset may vary with different material strength and thickness. The adjustment can be done using the adjustment wizards, or by a manual adjustment procedure: Adjustment using Wizard Machine Connection->Tool conﬁguration->Adjust Active Tool->Rotation Adjustment 1.
Page 70: Center Offset Adjustment
Kongsberg XP 13. If seen in the cutting direction, the knife enters to the left of the cut, the Angular Offset Value should be decreased. Repeat from point 5. 14. If seen in the cutting direction, the knife enters to the right of the cut, the Angular Offset Value should be increased.
Page 71: Tool Offset
Kongsberg XP 9. Press the Jog button for the return direction shortly, just to turn the Tool. 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.
Page 72: Maintain Tool List
Kongsberg XP The purpose of the calibration is to make sure the accuracy of the knife angle is optimal Manual notch angle Offset Machine Connection->Tool conﬁguration->Adjust Active Tool->Manual Adjustment An extra manual adjustment of the notch angle is possible. Please note that this offset will be added to the calibrated value found in the automatic calibration procedure.
Page 73 Kongsberg XP Delete Tool Use Delete Tool when a Tool is no longer in use. The deleted Tool will no longer be available in the Tool List in the Edit Layer dialog. Add Tool Use Add Tool to • Add new Tools •...
Page 74: Tooling System
Kongsberg XP 12. Tooling System 12.1. Introduction Knife Blades and Milling bits are extremely sharp. Take care when handling Knife Tools and Milling bits. Laser Radiation. Do not stare into beam! The tool head is equipped with a class II laser pointer. Emitted laser power < 1 mW.
Page 75: How To Replace A Tool
Kongsberg XP 12.3. How to Replace a Tool When mounting a tool onto the P1 or P2 Tool Positions, ensure that the Guide Pins and the electrical connector ﬁts those on the bracket. Use an Allen Key, 6 mm, to ﬁx the tool.
Page 76: Measuring Station
Kongsberg XP Inside each Tool, there is a Tool Board. By means of dip-switches, you can specify 4 unique Tool Numbers. The different Tool Numbers are deﬁned as follows: Tool Number Tool Board switch setting Tool 1 1 & 2 off Tool 2 1 on &...
Page 77 Kongsberg XP The Measuring Station eliminates the manual adjustment of tool height. The Measuring Station covers the following functions: • Calibrates the Measuring Foot. • Automatically measures the height of the tool tip. If you, for any reason, would like to add an...
Page 78: Hdu - Heavy Duty Unit
Kongsberg XP 12.6. HDU - Heavy Duty Unit HDU with ø150 mm Crease Wheel The Heavy Duty Unit is a single position Tool Head specially prepared for V-notch and HD Knife tools. In addition, the Tool Head can be equipped with a ø150 mm Crease Wheel, crease adapter and perforation wheel.
Page 79 Kongsberg XP A broad range of Crease Wheels with different shapes is available. How to mount / dismount Crease Wheels Insert / remove the Latch Pin. Insert / remove the Cotter Pin. Tool Adjustment For this tool, complete the following adjustments:...
Page 80: V-Notch Knife Tool
Kongsberg XP 12.6.2. V-notch Knife Tool Description The V-notch Knife Tool mounted on a Heavy Duty Unit. How to insert / remove the V-notch Knife Tool 1 Turn the V-notch Knife Tool correctly to ﬁt the Guide Pin. 2 Insert the two Latch Pins.
Page 81 Kongsberg XP How to replace a Knife Blade Warning: Sharp tool This picture shows how the Knife Blade is aligned using two Guide Pins (a and b) beneath the blade clamping. 1. Loosen the two screws (b) of the Knife Blade clamping.
Page 82 Kongsberg XP Adjustment Description Center Offset Adjust Tool sideways until centered. Tool Offset Adjust offset relative to Laser Pointer. For more information about how to run the Adjustment Wizards, see the Tool Conﬁguration chapter How to set the depth of the V-notch Knife 1.
Page 83 Kongsberg XP Note: V-notch Knife Adapters are available for different knife angles: 15 , 22.5 , 30 , 45 , 47.5 . There is also a VariAngle unit available for cutting any angle from 0 to 60 In this chapter, a 45 knife angle is discussed.
Page 84 Kongsberg XP V-notch Crease This is the default mode if neither V-notch cut nor Waste Cut are enabled. Performing two cuts in opposite direction to create a folding notch. Width Offset Width Offset is used to adjust the width between the two cut lines along and across ﬂute when...
Page 85: Hd Knife Tool
Kongsberg XP • Width Offset limitations: -50 mm < Width Offset < +10 mm / -2 in < Width Offset < +0.4 in. Decide if Waste Cut function is needed, mostly needed for corrugated plastics. • This illustration shows how the parameter dW is used to ensure a nice folding result.
Page 86 Kongsberg XP The HD Knife Tool is used for rigid board such as ReBoard and Triple Wall material. The Tool is limited to Straight Lines longer than 50mm (2”). The Tool is prepared for special, trapezoid shaped Knife Blades. How to replace a Knife Blade...
Page 87 Kongsberg XP How to insert / remove the HD Knife Tool 1 Turn the HD Knife Tool correctly to ﬁt the Guide Pin. 2 Insert the two Latch Pins. 3 Insert the Cotter Pins. Tool Adjustments For this tool, complete the following adjustments:...
Page 88: Crease Adapter
Perforation wheels with different pit to land ratios are suitable for multiple purposes in different materials. Before August 2019, Esko’ s portfolio of Perforation wheels had four different sizes: 3:3 mm, 5:5 mm, 7:5 mm and 10:10 mm From August 2019, the portfolio was extended.
Page 89 Kongsberg XP Perforation Wheel assembly Warning: Sharp tool Parts in assembly Ensure the path is clean. Fix cover properly. Push/pull the Perforation Wheel in/out from the 60 mm crease adapter.#...
Page 90: Bevel Knife 45
Kongsberg XP Tool Adjustment For this tool, complete the following adjustments: Adjustment Description Lag Setting The nominal value for Perforation wheels is 0 mm. Note: The Lag value can be used to adjust overshoot and Lead-in of Perforation Cut Lines.
Page 91 Kongsberg XP • Loosen the two screws holding the blade clamp. • Pull out the old Knife Blade. • Insert the new blade. • Ensure the blade align exactly with the alignment pins. • Fix the blade clamp. At left, the clamp is removed just to show how to align the Knife Blade.
Page 92: Foam Knife
Kongsberg XP 12.7. Foam Knife Description The Foam Knife Tool Head is mounted onto the P1–position. Note: Be careful where to place the Foam Knife Tool when not in use. If the Tool Head is left on a table surface, the Knife Blade might be exposed, as the material hold down wheels moves up.
Page 93 Kongsberg XP A set of Knife Protection Handles are available. Use them for safe knife handling. When not in use, protect the Knife Blade using the handle. How to replace the Knife Adapter Loosen the ﬁxing screw, replace the adapter and ﬁx it again.
Page 94: Dual Hdu - Dual Heavy Duty Unit
Kongsberg XP • Reduce the Cutting Speed (from Opened Job->Layer). • Cut in two or three passes, each pass going a step deeper (Multi-pass on page 44). Tool Adjustment For this tool, complete the following adjustments: Adjustment Description Lag Setting The Knife Lag depends upon the Blade Adapter.
Page 95 Kongsberg XP P1.1 P1.4 Comments 150 mm Crease Wheel Perforation Wheel For Crease and Perforation 150 mm Crease Wheel 60 mm Crease wheel For different points or pressure distribution 15 / 26 / 60 mm Crease Adapter Perforation Wheel For Crease and Perforation...
Page 96: Dual Hdu Hd Perf Position
Kongsberg XP 12.8.1. Dual HDU HD Perf Position Description The Dual HDU HD Perf tool position is for 60 mm wheels, Perforation or Crease. The position is identiﬁed by the system as “HD Perf”. It delivers the equivalent of 50 Kg [110 lbs.] downforce.
Page 97 Kongsberg XP Be aware of sharp Perforation Be aware of the tight gap Be aware of sharp knifes in P1.1 between HD Crease and HD Perf. Wheel when mounting tools in when mounting HD perf. P1.1. Curved geometries If using the HD Perf position for circles or curves of any kind, make sure to convert in a clockwise direction.
Page 98: New Mounting Procedure For Hd Insert Tools
Kongsberg XP *) Tip: When adjusting Tool Height for perforation or Crease wheels, move the tool outside the material surface. Set the height so that the tool tip touches the table top surface before manually jogging the tool through the material. Complete wizard and inspect Crease/perforation result (should yield a good quality Crease or perforate all the way through material).
Page 99 Kongsberg XP To mount V-notch in the Dual HDU, remove wheel from HD Perf position ﬁrst. It is not possible to correctly mount the V-notch tools with Perforation Wheel still mounted. HD Knife tool safety cover The HD Knife tools come with an additional safety cover. If you have bought a HD Knife Tool before Q3 2019, the axle-bar that holds this safety-cover must be exchanged (if you want to use your HD Knife Tool in the Dual HDU).
Page 100: Variangle Unit
Kongsberg XP 12.9. VariAngle unit 12.9.1. Introduction The VariAngle unit is a tool for position P1 on Cxx and XP platform. It is specially prepared to cut at different angles (also known as V-notching). The tool can automatically change the angle of the knife between 0 and 60 degrees, in 0.5-degree...
Page 101: Tool Description
Kongsberg XP To protect the operator, the Please be aware that during In the case of the tool being knife will move to the max angle, a job, the knife might point selected while the machine is and the tool will turn backwards straight towards the operator.
Page 102: Description Of Knife Blade Adapters
Kongsberg XP How to mount / dismount knife blades to adapters The knife blade is ﬁxed to the adapter with a mounting plate with guide pins and screws. The guide pins ensure correct combination of knife blade and adapter, wrong combination will not ﬁt.
Page 103 Kongsberg XP Standard adapter, for standard/long knife blades, included with the tool. • Straight cut up to 30 mm / 1.18 in. material thickness V-notch cut at 45 degrees up to 20 mm / 0.79 in. thickness • • V-notch cut at 60 degrees up to 16 mm / 0.63 in. thickness Long adapter for short knife blades, optional.
Page 104: Tool Adjustment
Kongsberg XP 26 mm / 1.02 in. 28 mm / 1.10 in. 30 mm / 1.18 in. Material thickness and notch angle 12.9.5. Tool adjustment Unique adapter identiﬁcation The adapters are recognized by the machine, and the VariAngle unit will have different adjustment values for each adapter.
Page 105: Basic Modes Of Operation
Kongsberg XP An eLearning (English) shows how to adjust the VariAngle unit correctly: https://learning.esko.com/course/view.php?id=56#section-2 For more information about how to run the adjustment wizards, see Tool Conﬁguration on page 64 12.9.6. Basic modes of operation Note: A material thickness must always be deﬁned when using the VariAngle unit. Select an existing material from the Job window, or create a new material with a thickness from Advanced ->...
Page 106 Kongsberg XP The V-notch Cut function will perform an angled cut in the material. Note that the cut direction of the line is important as it will decide towards where the angled surface is facing. V-notch Crease will perform two cuts facing each other independent on the speciﬁed cut direction.
Page 107: Workflows, Set-Up And Optimization
Kongsberg XP For a 90 degrees folding angle, the nominal recommendation is to decrease the width of the cut by twice the bottom liner thickness. The Width offset function can be used to adjust the width between -50 to 10 mm / -1.97 to 0.39 in. Example: If your liner is 1 mm / 0.04 in. thick, the Width offset should nominally be -2 mm / -0.08 for a 90 degrees fold.
Page 108: Advanced Operations
Kongsberg XP • Get the best out of iPC, manual (English): Appendix 1 - iPC Resources # Setting up Tooling presets. 12.9.8. Advanced operations To enable these functions, open the Conﬁgure Tools dialogue: Menu Bar->Advanced->Conﬁgure Tools... Reverse operation If the job has print on the front but should be cut from the back, the Reverse Operation function can be...
Page 109 Kongsberg XP If the VariAngle unit is used as a regular knife tool If the same shape is cut at an angle, e.g. 45 (0 degrees cut) to cut out a simple rectangle, the degrees, the difference might look like the...
Page 110 Kongsberg XP The illustrated above shows Rotational Compensation. This will be applied for all lines in the selected layer. Note: This compensation will only be valid for the given layer and will not affect the angular offset in the Tool conﬁguration menu. The knife blade can be compensated between -3 and 0 degrees.
Page 111: Work Area Limitations
Kongsberg XP Use the Multi-pass Depth and Web Thickness settings to do this within a layer. In the example, the material thickness is 16 mm / 0.63 in. Specifying the full material thickness minus the liner thickness in the Multi-pass Depth ﬁeld will make the system recognize that it should cut the line in two passes.
Page 112: Material Lift
Kongsberg XP 12.9.10. Material lift If the material is being lifted up from the cutting table during a Job, then the following efforts might help: • Optimize the Vacuum effect, see Optimize vacuum effect on page 42. • Increase the amount of material between the outer cut lines and the edges. The amount needed is material dependant, and might also be dependant of the cut direction.
Page 113: Tool Head Description
Kongsberg XP Replacing a chuck Replacing a chuck is described in detail in Chuck Change and Cleaning on page 126. This chapter is included just to remind you how important it is to use the Chuck Changing Tool available and a dummy bit to ensure correct mounting: From left: Chuck change assembly.
Page 114 Kongsberg XP 1. Milling bit. 2. Chuck. The HPMU is equipped with one 6 mm chuck on delivery. 3. Spindle HPMU Park Position A HPMU Park Position is available on the gallows stand. Use the park position for safe HPMU Tool Head storage.
Page 115: Safety Issues
Kongsberg XP Suction House, adjustable height On HPMU, you can lock the Suction House in any height; still, it is allowed to move upwards. This function is useful in order to: 1. Adapt to different material thicknesses. 2. Allow false air input in order to reduce suction force.
Page 116 Kongsberg XP • 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 117: Precautions
Kongsberg XP Milling bits are very sharp – handle with care. Milling stop time The milling spindle does not stop instantly. Always ensure that the red lamp has stopped ﬂashing, and by visual inspection that the milling bit has come to a complete standstill before touching it.
Page 118 Kongsberg XP The HPMU 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. Too high Spindle Power consumption indicates critical conditions for the motor and immediate actions should be taken: 1.
Page 119 Kongsberg XP 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 will destroy the Spindle.
Page 120 Kongsberg XP Long Term Storage More than 4 weeks storage of a Spindle or a HPMU requires: 1. Turn the Spindle rotor by hand every 4 weeks to reallocate the bearing lubricant. 2. The Spindle must be stored horizontally. Remove sharp bit and close the chuck on a dummy bit.
Page 121: Milling Advice
Kongsberg XP 12.10.5. Milling advice Follow this advice for obtaining the best possible milling results. Milling Bits For thin materials, use bits with short cutting length. For best performance and minimum wear, do not let the bit stick out more than necessary.
Page 122 Kongsberg XP 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. Bits with small cutting diameter (3-4 mm; 0.12-0.16 in) are more balanced than bits with larger cutting diameter Thus, they can run with higher RPM, normally 60.000.
Page 123 Kongsberg XP Feed Rates One-ﬂute Bits do have a good chip ﬂow, and allow for large feed rates. 0.1-0.2 mm/tooth (0.004-0.008 in/tooth) can be a starting point for optimization in most materials: This gives a feed rate of of 4-8 m/min (2.6-5.2 ips) at 40.000 RPM, and 6-12 m/min (3.9-7.9 ips) at 60.000 RPM.
Page 124: Cleaner Device
Kongsberg XP 12.10.6. Cleaner Device Cleaning the suction house is simple using a Cleaner Device, which is available as an option. 12.10.7. Bits and Bit Change How to insert / replace a milling bit Warning: Sharp tool Ensure the Spindle is not running, and that the red light is off.
Page 125 Kongsberg XP Observe that the milling bit is not rotating, by visual inspection. Use a cloth to hold the bit. Move the Chuck Open/Close lever down to open the Chuck. Put the bit in a proper storage container. Insert a new milling bit.
Page 126: Chuck Change And Cleaning
Kongsberg XP Regularly, perform a Chuck cleaning, following the dedicated procedure; Chuck Change and Cleaning on page 126. Note: Never use Compressed Air for cleaning. If a Milling Bit is stuck If a Milling Bit is stuck in the chuck, the probable cause is low air pressure.
Page 127 Kongsberg XP Procedure Place the Tool Head on the table. Open the chuck and remove any bit. Note: Never apply Compressed Air for cleaning. Apply the 17 mm key to hold the Spindle Rotor. Note: Do not turn the rotor when Chuck is in open position.
Page 128 Kongsberg XP 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 129 Kongsberg XP 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 130: Bit Slipping, Chuck Change
Kongsberg XP Chuck Maintenance Kits are available in the Esko Store on www.esko.com. 12.10.9. Bit Slipping, Chuck Change Even though the chuck is expected to have a long lifetime, replace it immediately if you experience any problems as: 1. Bit slipping.
Page 131: Tool Adjustment
Kongsberg XP 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 132: Miscellaneous
Kongsberg XP U = Milling Underlay The Table Top Reference function is carried out on top of the Milling Underlay The Tool Height is measured automatically. If, after a test cut, you want to modify the Milling Depth, this is possible from the Tool Height Adjustment dialog.
Page 133: Lubricool (Multicut-Hp Only)
Kongsberg XP Suction House Clean the Suction House when necessary. Use acetone and a q-tip. A smooth surface will ease the chip removal. Warning: Regularly inspect and clean the suction house to prevent clogging. Failing to do so could in worst case result in a ﬁre when a hot milling bit is in contact with the debris.
Page 134 Kongsberg XP LubriCool mounted on HPMU. • A - inspection window. • B - Suction cup with nozzles. LubriCool control unit How to use LubriCool is on when the Vacuum Cleaner is on. For materials where lubrication is not suitable, use the ON/OFF switch on the LubriCool Control Unit to switch off lubrication.
Page 135 Kongsberg XP Inspection Opening When the LubriCool unit is on, you can see light in the control relays inside the unit. For LubriCool, use this oil only: Accu-Lube LB-5000 Use Nozzle Unit or Suction Ring Nozzle Unit Suction Ring...
Page 136: Chiller No 1 (Blue Top) For Hpmu
Kongsberg XP is delivered with one Nozzle Unit for the LubriCool function and one Suction Ring with just a brush, and with bigger suction opening. • Use the Nozzle Unit when the LubriCool function is beneﬁcial only! For all other materials, especially MDF, use the Suction Ring! •...
Page 137: Chiller Heater, Operation
Kongsberg XP This is chiller 1, replaced in October 2016 by a new model named Chiller 2016. 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.
Page 138 Kongsberg XP Press On/Off button to start the heater. The letters BCS are displayed. To turn unit off, push and hold the button for 3 seconds. Media temperature is displayed. Green light on - the unit is on, and the speciﬁed temperature is reached.
Page 139: Chiller, Error Conditions
Kongsberg XP Program Temperature range Temperature range to Hysteresis from ( Factory Setting Correct factory setting is Program = 5 and temperature = 26 oC (Chiller with heater). 12.11.3. Chiller, Error Conditions One common error signal is routed from the Chiller system to the inverter and further into the control system.
Page 140: Startup
Kongsberg XP Chiller 2016 and Chiller 2020 refers to two similar models introduced those years. Chiller 2020 differs from previous models by being a heat exchanger, which will not be able to lower the temperature below ambient. Speciﬁcations Dimensions W x D x H = 480 x 580 x 430 mm / 19 x 23 x 17 in.
Page 141: Error Conditions
Kongsberg XP • Signal cable (to inverter) is connected to the chiller unit. • Chiller ﬂuid level should be MAX. If not, ﬁll with fresh water. • If water temperature is too low, wait for the temperature to attain proper value ( 19 C / 66 F ).
Page 142: Vibracut
Kongsberg XP More information is available from the Operating instructions for the chiller. 12.13. VibraCut The VibraCut is available in two models: VibraCut Running with 6000 RPM and amplitude +/- 0.15 mm (0.006 inches), this tool is recommended for light duty Corrugated Materials.
Page 143 Kongsberg XP Pull straight out to remove the Knife Foot. Loosen the screw A and replace the Knife Blade. Ensure the Knife Blade has correct position relative to the screw. Push the Knife Blade down while the screw is ﬁxed.
Page 144: Rigid Material Knife (Rm Knife Tool)
Kongsberg XP Adjustment Description Nominal value is 0-3 mm. Tool Height Measured automatically, possible to add an Offset Value. Tool Rotation Adjust Tool Angle tangential to Moving Direction. Center Offset Adjust Tool sideways until centered. Tool Offset Adjust offset relative to Laser Pointer.
Page 145: Hiforce Knife
Kongsberg XP Ensure the Knife Blade is correctly aligned. No additional adjustments are necessary, as the tool height is measured automatically. Tool Adjustment For this tool, complete the following adjustments: Adjustments Description Lag Setting The Knife Lag depends upon the Blade Adapter.
Page 146 Kongsberg XP As the name indicates; this tool is prepared for a higher tool pressure compared to the Static Knife. The tool is prepared for a wide range of Knife Blades. To reduce material tear and also to keep the material down as the Knife Blade is pulled out, a Knife Foot is available.
Page 147 Kongsberg XP Extreme care should be taken when inserting the Knife Foot again. Keep ﬁngers away from Knife Blade as illustrated at left. Tool Adjustment For this tool, complete the following adjustments: Adjustment Description Lag Setting The Knife Lag depends upon the Blade Adapter.
Page 148: Psaligraphy Knife
Kongsberg XP 12.16. Psaligraphy Knife Note: iPC version 2.0 or higher is required to run this tool. Psaligraphy Knife is a tool for cutting of ﬁne details in paper and folding carton. Replace Knife Blade Warning: Sharp tool For Knife Blade change, remove the foot.
Page 149: Presscut
Kongsberg XP Adjustment Description Lag Setting The Knife Lag depends upon the Blade Adapter. Nominal value is 0-3 mm. Tool Height Measured automatically, possible to add an Offset Value. Tool Rotation Adjust Tool Angle tangential to Moving Direction. Center Offset Adjust Tool sideways until centered.
Page 150 Kongsberg XP This ﬁgure shows how the Knife Blade is ﬁxed inside the PressCut Knife Tool. The friction between the Alignment Pin A and the Knife Blade keeps the Knife Blade in place. A special hand tool is available as an aid when replacing Knife Blades.
Page 151 Kongsberg XP The Knife Pressure is modiﬁed if Speed Dependent Tool Pressure is speciﬁed, see below. During the tool down movement, the knife moves down until the material surface is detected and the proper Knife Pressure is achieved. The Knife Pressure needed will vary depending upon the material.
Page 152: Rotacut
Kongsberg XP 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 153 Kongsberg XP • It is not suitable for curves with small diameter. • It is not suitable for designs containing short lines in combination with sharp angles. RotaCut is prepared for Decagonal Knife Blades, ø25 mm / 1 inch. How to replace the Knife Blade...
Page 154 Kongsberg XP 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 155: Braille Tool
Kongsberg XP Correct setting of Lag- and Width - values are shown. Lag: 3.5 mm / 0.14 inch Width: 7.0 mm / 0.28 inch Use the Lag and Width parameters to achieve proper corner cutting. 12.19. Braille Tool 1. Keep the tool in upright position during this process.
Page 156 Kongsberg XP Braille Tool setup In order to create high quality consistent braille patterns you should perform Tool Height and Tool Offset calibrations. Note: It is crucial that the Tool Height is correctly set before running this tool. The nominal value is Tool Height = Material Thickness.
Page 157 Kongsberg XP 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 158 Kongsberg XP Example using 3mm Dibond: 1,07mm – 3mm = -1,93mm Spindle RPM Spindle RPM is material dependent and may require experimentation. The values shown in the illustration are suitable for 3mm Dibond. Drill holes Drill holes check box should be enabled.
Page 159: Corruspeed Knife
Kongsberg XP 12.20. CorruSpeed Knife Note: iPC version 2.0 or higher is required to run this tool. CorruSpeed Knife tool is made especially for cutting corrugated materials. Maximum material thickness: 7 mm/0.28 in. Maximum knife edge height: 6.5 mm/0.26 in; requires minimum 0.5 mm/0.02 in.
Page 160 Kongsberg XP 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 161: Tool Adjustment
Kongsberg XP For Knife Blade change, remove the foot. • The locking screw will always point towards the cutting direction • Note: Be extremely careful when mounting the foot. • Observe the alignment pins. • After a blade change, the tool depth should be checked again.
Page 162 Kongsberg XP Braille Tool will enable you to create signage readable by visually impaired people. Braille Tool is prepared for use in combination with HPMU. Braille Tool, how to add spheres 1. Keep the tool in upright position during this process.
Page 163 Kongsberg XP Plunger The tool is equipped with a plunger that serves two purposes: 1. To force the spheres into the internal funnel. 2. Indicate the number of spheres remaining in the tool. If the groove is no longer visible it means that there is a limited number of spheres left in the tool.
Page 164 Kongsberg XP selected substrate. It is important that the piece of tape ﬁts within the hole in the measuring foot with good margins. Insert the Braille Tool in the HPMU tool head. Open up the Tool Adjustment dialog. Select Braille Tool and press Adjust Active Tool…...
Page 165 Kongsberg XP Layer: Braille Drilling (HPMU) Velocity Z Velocity Z is material dependent and may require experimentation. The value shown in the illustration is suitable for (and has been tested with) 3mm Dibond. Z-axis depth Z-axis depth is determined by the material thickness and hole depth.
Page 166: Drill / Pen Tool
Kongsberg XP Drill Holes Drill Holes check box must be enabled for the Braille Tool to work properly. Creating a Braille Job ﬁle Braille grade 1 & 2 Grade 1 braille is a letter-by-letter translation of texts. If you wish to create Grade 1 braille signage you can use any available braille font. These fonts may be freely available on the internet.
Page 167 Kongsberg XP Inserting a tool - push down until the Tool is locked in position. To remove a Tool - press the Release Button. Pen/Drill Motor Connector: To release, grab the housing and lift straight up. To insert, move connector carefully down and turn it until it ﬁts.
Page 168: Drill Tool
Kongsberg XP 12.23. Drill Tool This Drill Tool is for use in re-board and other paper - based materials. The Tool is prepared for drill bits 0.5 – 6 mm (0.02 - 0.24 inches). How to replace a Drill Bit Push the Drill Bit towards the bottom of the chuck.
Page 169: Ballpoint Pen
Kongsberg XP 12.24. Ballpoint Pen Ballpoint Pen is available for pen drawing. Tool pressure is adjustable by a knob on top of the tool. Tool Assembly and Pressure Adjustment A - Inner sleeve. The Ballpoint Pen reﬁll is ﬁxed inside the sleeve using a screw.
Page 170: Measuring Foot
Kongsberg XP 12.25. Measuring Foot The Measuring Foot (M) has 3 functions: 1. Measure the thickness of the material on the table 2. Map Table Top Surface. 3. Calibration of the Measuring Station. No adjustments are necessary. 12.26. Laser Pointer The Laser Pointer (L in the illustration) is a Class II laser beam Pointing Device.
Page 171: Maintenance
Kongsberg XP 13. Maintenance 13.1. General Warning The Main Power should be switched off before cleaning is carried out. More detailed information about C system maintenance is available in the Maintenance Manual. 13.2. Daily Maintenance Inspect • Inspect the equipment in order to prevent any irregularities.
Page 172: Monthly Maintenance
Kongsberg XP Photo Cells The surface of the Transmitter and Receiver should be carefully cleaned using light soap and clean water. Air Pressure Reduction Valve The automatic draining action of the Air Pressure Reduction Valve should be controlled: 1. Switch off the Air Compressor and allow the air pressure to fall.
Page 173 Kongsberg XP As grease is applied through the extension tube and onto the gear wheel, it is important that the grease is distributed around the wheel. • In one spot, apply just a small amount of grease (one push).
Page 174 Kongsberg XP Y axis gear: Racks The racks in X1, X2 and Y should be re-greased:...
Page 175 Kongsberg XP X1 (above) X2 (above) Y (above) Procedure Use the soft brush to apply grease to the racks. No covers have to be removed to complete this procedure. Apply small dots of grease every 25 cm / 10 inch along the entire length of the rack, on X1 and X2 side.
Page 176 Kongsberg XP Repeat the procedure for Y – along the traverse. Conveyor belt with tension control (option) Check belt tension by the indicators on both sides. If the green mark is outside the range of the line, the conveyor should be checked by a trained technician.
Page 177: Maintenance, External Equipment
Kongsberg XP By activating the sensors by hand, the function of the system can be veriﬁed. Vacuum Table (no conveyor) Every other month, or after the table surface has been cleaned, the closed vacuum holes in the surface should be opened in order to retain the hold-down eciency.
Page 178: Spare Parts
Kongsberg XP It is recommended to check the foam rubber on the Waste Handling kit daily for damage and if it is worn out. 13.6.2. Spare Parts Spare parts available: Description Part no 42468512 TAKEUP_GASSPRING 42468520 TAKEUP_GASSPRING GUIDING ROLLER 42468538...
Page 179: Fuse Replacement
Kongsberg XP 14. 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 Note: Some equipment described might be optional. 14.1. MPU fuses MPU Location Note: MPU location is model dependent.
Page 180 Kongsberg XP 3. Repeat for each fuse. 4. Replace base cover 5. Insert main power cable into the wall socket and turn main power on. Fuse Details All fuses are: 1 1/4 x 1/4 in (6,3 x 32 mm) Fuse location...
Page 181 Kongsberg XP Fuse Location 1 – 8/24A AC ampliﬁer X1 2 – SCU unit Procedure 1. Remove X1 cover. 2. Remove cover from AC ampliﬁer unit. 3. Check fuses F2 – F5 with ohm - meter. If blown, replace with a new identical fuse.
Page 182 Kongsberg XP X2 Ampliﬁer Location Fuse Location Procedure 1. Remove X2 cover. 2. Remove cover from AC ampliﬁer unit. 3. Check fuses F2 – F5 with ohm - meter. If blown, replace with a new identical fuse. 4. Replace covers.
Page 183: 183
Kongsberg XP Fuse Details T 10A 250V (5 X 20 mm). 14.4. Y Y Ampliﬁer Location Fuse Location 1 – Y-motor with encoder. 2 – TCU. 3 – AC ampliﬁer for Y. 4 – Z1 – motor. 5 – Z2 – motor...
Page 184: P1/P2 Fuses
Kongsberg XP Procedure 1. Remove Y cover. 2. Remove cover from AC ampliﬁer unit. 3. Check fuses F2 – F5 with ohm - meter. If blown, replace with a new identical fuse. 4. Replace covers. 5. Insert main power cable into the wall socket and turn main power ON.
Page 185 Kongsberg XP Fuse Location 1 – Y-motor with encoder. 2 – TCU. 3 – AC ampliﬁer for Y. 4 – P1 – motor. 5 – P2 – motor Procedure 1. Remove Y cover. 2. On the TCU – unit, check fuses Fz1 and Fz2 with ohm - meter. If blown, replace with a new identical fuse.
Page 186: Fuses On Various Tools
Kongsberg XP 14.6. Fuses on various tools 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.
Page 187: Chiller Fuse, Hyfra (Blue Top)
Kongsberg XP Tool Head Function Fuse Fuse Fuse Type Size 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) RM Knife Tool Tool Rotation T 4A 125V NANO (42444828)
Page 188: Heater For Chiller Fuse
Kongsberg XP Fuse location Pull out the fuse holder Turn the fuse holder 90 deg. Now you have easy access to the fuse. 1 - Spare fuse 2 - Fuse in action Fuse when mains 115V: T 2A 250V (5x20 mm)
Page 189: Sound Insulating Box, Circuit Breaker For Fan
Kongsberg XP 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 190: Takeup Unit, Fuse Replacement
Kongsberg XP The ON/OFF switch is in a middle position. • Find and remove the root cause for the problem. • Set the ON/OFF switch A to ON. 14.11. TakeUp Unit, Fuse replacement The fuses are mounted on the main electrical mounting plate behind the sheet metal cover on the right side of the machine.
Page 191: Motorized Roll Feeder, Fuse Replacement
Kongsberg XP Fuse F2: T2.5 A, 250V, 5x20mm (44347540) The same fuse size is used regardless 115V/230V. 14.12. Motorized Roll Feeder, Fuse replacement The fuses are mounted on the main electrical mounting plate behind the sheet metal cover on the right side of the machine.
Page 192 Kongsberg XP...
Page 193: Roll Feeder
Kongsberg XP 15. Roll Feeder A – Bracket Position Pin (push the center button to release the lock). B – Roll Holder Bracket. C – Brake Position Locker. D – Roller Brake. E – Brake Tension adjustment. Turn clockwise to increase tension.
Page 194: Collector Basket
Kongsberg XP 16. Collector Basket The unit is placed in the unload end of the conveyor belt (front of table). The unit is prepared for rigid pieces up till 200x200 mm / 8x8 in, or ﬂexible materials. Maximum load weight is 30 kg / 65 lbs.
Page 195: Takeup Unit
Kongsberg XP 17. TakeUp Unit 17.1. Introduction Scope This manual refers to the TakeUp Unit The manual contains useful and important information for proper functioning and maintenance of the machine. It also contains important instructions to prevent accidents and serious damage prior to and during operation of the machine, and it enables the product to perform as safely and ﬂawlessly as possible.
Page 196: Machine Description
Kongsberg XP • Service and maintenance are not carried out strictly in accordance with the instructions, repair work is not carried out by our personnel or has been performed without prior written consent. The TakeUp Unit is modiﬁed without prior written consent; non-original parts are used.
Page 197: Safety
Kongsberg XP The emergency stop on the top of both sides of the TakeUp Unit can be used to stop the machine immediately. The dancer roller controls the turning direction of the TakeUp Unit . When there is new media provided to the TakeUp Unit by for example a cutting table, the dancer roller will follow the media and lowers in the machine.
Page 198 Kongsberg XP DANGER: VOLTAGE Only qualiﬁed personell is authorised to open these parts of the machine to perform maintenance operations. In this case, ensure that the power is turned off. Do not remove or open the left metal safety covers of the machine, you may get injured by voltage or rotating parts.
Page 199: Features And Components
Intended Use The TakeUp Unit is only intended to be used for winding up media. Any different or additional use of the machine is considered improper and Esko is not responsible for any resulting damage to machine or individuals. Intended use does include: •...
Page 200: General Operation
Kongsberg XP A - Emergency switch B - Autogrip shaft C - Dancer roller D - Frame E - Control panel D - Waste handling kit 17.5. General operation Control positions The TakeUp Unit is normally operated from the right side of the machine.
Page 201: Applying Winding Material
Kongsberg XP A - Jog forward/backward The jog button turns the autogrip shaft slowly forwards or backwards. To Jog, the winding direction button has to be set in position: 0. B - Winding direction The winding direction button controls the winding direction of the TakeUp Unit.
Page 202: Start The Takeup Unit
Kongsberg XP Add a 3 in. coil on the Autogrip shaft. Bring the material with the Kongsberg table to the TakeUp Unit till the material is fed far enough underneath the waste handling kit to reach the Autogrip shaft. Take the winding material underneath the dancer roller and paste it with tape in a straight line onto the coil.
Page 203: Using The Autogrip Shaft
Kongsberg XP The TakeUp Unit is activated. The machine starts processing. It stops when the dancer roller is in neutral position, the power button is switched off or when the emergency stop is activated. Attention: The TakeUp Unit does not stop automaticly when the waste roll is full.
Page 204 Kongsberg XP Attention: During operation, the locking rings need to be in locked position, to ensure safe operation and avoid risks for the operator. Locking ring in unlocked position Locking ring in locked position Exchange media rollers The media needs to be cut when the media roll has reached it’ s maximum diameter or when the roll has to be exchanged.
Page 205 Kongsberg XP The dancer roller (D) in the TakeUp Unit controls the winding of the media. When the dancer roller lowers the winding unit will start winding, till the dancer roller rises to the start position. Resetting TakeUp Unit The dancer roller will move to its lowest position when a roll of material is completed.
Page 206: Mrf Quick Start Guide
Kongsberg XP 18. MRF Quick start guide 1. Make sure the Automatic winding direction switch (A) is switched off. 2. Release Autogrip shaft a. Turn the shaft so the triangular warning sticker is facing up b. Push open the Safety chuck 3.
Page 207: Mrf Weight List
Kongsberg XP 19. MRF Weight list For commonly used materials, print out and ﬁll in this list. Material Number Material Number...
Page 208: Vacuum Cleaner
Kongsberg XP 20. Vacuum Cleaner 20.1. Vacuum Cleaner, Zeﬁro 20.1.1. 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 209 Kongsberg XP 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 210: 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. 20.2. Vacuum Cleaner, High-capacity, TB ESKO 20.2.1. How to use Introduction 1 – Filter Chamber 2 –...
Page 211 Kongsberg XP 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 212 Kongsberg XP Use Plastic Bag in Material Container 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.
Page 213: Compact Vacuum Cleaner
Kongsberg XP 20.3. Compact Vacuum Cleaner 20.3.1. How to use 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).
Page 214 Kongsberg XP 5. Lift and turn the container to release it from the ﬁxture. 6. Empty the container.
Page 215: Install Software
Kongsberg XP 21. Install Software For information about software installation, see the Installation Manual for the actual machine. Available on the Documentation DVD.
Page 216: Frequently Asked Questions
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 217: 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 218 Kongsberg XP If there was a software update recently, check if the ﬁrmware on the machine and iPC are of the same version Check the serial connection between PC and MCU Check the connection at the emergency button...

Esko Kongsberg XP User Manual

1 Preface

2 Change Record

3 Introduction

4 Using this Manual

5 Safety Regulations

6 System Description

7 Basic Operations

8 Prepare for a Job

9 How to Procedures, Advanced

10 System Setup

11 Tool Configuration and Adjustment

12 Tooling System

13 Maintenance

14 Fuse Replacement

15 Roll Feeder

16 Collector Basket

17 Takeup Unit

18 MRF Quick Start Guide

19 MRF Weight List

20 Vacuum Cleaner

21 Install Software

22 Frequently Asked Questions

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Summary of Contents for Esko Kongsberg XP