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Esko Kongsberg XL User Manual

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Kongsberg XL
User Manual
09 - 2020 | XL

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Summary of Contents for Esko Kongsberg XL

  • Page 1 Kongsberg XL User Manual 09 - 2020 | XL...

  • Page 2: Table Of Contents

    Kongsberg XL Contents 1. Preface................................. 7 2. Change Record............................8 3. Introduction..............................9 3.1. Welcome.............................9 3.2. FCC conformity statement........................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..........................11 5.
  • Page 3 Contents 6. System Description..........................25 6.1. Naming conventions........................25 6.2. Main Power Switch......................... 25 6.3. Operators Panel..........................25 6.4. Variable Blow Back..........................27 6.5. Pressurized Air system........................28 6.6. Application programs available..................... 28 7. Basic Operations............................. 29 7.1. Power On Sequence........................29 7.2.
  • Page 4 Kongsberg XL 10.7. Reference Points and Coordinate System.................. 50 10.8. Table Speed........................... 51 10.9. Table Acceleration......................... 52 10.10. Jog Settings..........................52 10.11. Set Table Top Reference......................52 10.12. Milling Unit Setup........................53 10.13. Board Size............................54 11. Tool Configuration and Adjustment....................55 11.1.
  • Page 5 Contents 12.8.11. Tool Adjustment......................100 12.8.12. Table Top and Height Adjustment................101 12.8.13. Miscellaneous........................102 12.9. Chiller no 1 (blue top) for MultiCUT-HP..................103 12.9.1. Introduction........................103 12.9.2. Chiller, Error Conditions....................104 12.9.3. Chiller Heater, Operation....................104 12.10. Chiller 2016 / Chiller 2020 for MultiCUT-HP................106 12.10.1.
  • Page 6 15.6. Sound Insulating Box, Circuit Breaker for fan................155 16. Vacuum Cleaner..........................156 16.1. Vacuum Cleaner, Zefiro......................156 16.1.1. How to use........................156 16.2. Vacuum Cleaner, High-capacity, TB ESKO.................158 16.2.1. How to use........................158 16.3. Compact Vacuum Cleaner......................161 16.3.1. How to use........................161 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 XL 2. Change Record Description Date dd-mm-yy 30-05-2017 jhbe For XL, this is the first edition. 30-05-2017 jhbe Work space limitation when using V-notch or Bevel knife, information added.

  • Page 9: Introduction

    Kongsberg XL 3. Introduction 3.1. Welcome Welcome to the User Manual for Kongsberg XL-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).

  • Page 10: Using This Manual

    Kongsberg XL 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 XL • - 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: Safety Regulations

    Kongsberg XL 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 13: 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.   ...

  • Page 14: Warning Sign Explanation

    Kongsberg XL 5.5. Warning sign explanation High voltage warnings • Main Power Unit (MPU) External components are not disconnected by the mains connection of the cutting table. Do not remove the cover of this unit until the mains connection for...
  • Page 15 Kongsberg XL Note: Different instruction for Cxx and Xxx. • Starter unit The starter unit is not disconnected by the mains connection of the cutting table only. Do not remove the cover of this unit until the mains connections have been removed from the socket outlet for vacuum pump, vacuum cleaner, IBAG inverter and chiller, in addition to the cutting table.
  • Page 16 Kongsberg XL • Between X-axis end stopper and traverse wagon. Moving Parts Potential areas with a risk of being hit by Moving Parts are marked with the Moving Parts sign. These areas are: • Both traverse ends. • Y carriage.

  • Page 17: Attention Areas

    Kongsberg XL 5.6. Attention Areas 5.6.1. 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. 5.6.2. Moving Parts, Laser Radiation and High Voltage 5.6.3.

  • Page 18: Ejection Of Parts When Milling

    Kongsberg XL 5.6.5. Ejection of parts when milling Ejection of parts is a potentional risk when milling. Always use eye protection to prevent injury from breaking milling bits or small pieces of processed material. See also Safety issues on page 83 in the section for milling.

  • Page 19: Safety Devices

    Kongsberg XL 5.7. Safety devices 5.7.1. Overview Device no Description Main Power Switch Emergency Stop Button Warning lamp/status lamp (Y carriage) / milling spindle running (milling unit) Photo cell supervision, Dynaguard Traverse Stop Switches, Dynaguard 5.7.2. Emergency Stop Button Switch positions: - Emergency Stop is switched OFF.

  • Page 20: Dynaguard Safety System

    3. Observe that Servo Power is switched on, 4. Press Start to continue. 5.8. Protective equipment For the operator(s), Esko recommends the following Protective Equipment: Close-fitting clothes to avoid being caught by the beam or the tool head which can cause injuries.

  • Page 21: Procedures In Case Of Malfunctions

    78.5 – 83.5 dBA and a maximum level of 98.5 dBA. 5.9. Procedures in case of malfunctions Trouble-shooting and repair shall be executed by Authorized Personnel only. Contact a Esko Service Organization. 5.10. Check before operation Before operating the equipment, check the following: • Electrical cables without damage •...

  • Page 22: Residual Risk

    Kongsberg XL 5.11. Residual Risk, Despite all safety protection means incorporated in this machine, there are some Residual Safety Risks to be aware of: Beneath traverse end The low part of the traverse ends is un- protected. Actions: • Children are not supposed to be in the machine area.
  • Page 23 Kongsberg XL 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 Kongsberg XL Stop time of the milling spindle is up to 4 seconds. This is sufficient time to access and touch the milling bit before it has come to a stop. It is crucial that the operator is trained to...

  • Page 25: System Description

    Kongsberg XL 6. System Description 6.1. Naming conventions X - X-axis X1 - X1 end of traverse Y - Y-axis X2 - X2 end of traverse Z - Z axis The arrows indicates positive moving direction. 6.2. Main Power Switch Switch positions: - the Main Power to the machine is switched OFF.
  • Page 26 Kongsberg XL Mains Power on/off indication. Servo Power On Servo Power on/off control. 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.

  • Page 27: Variable Blow Back

    Kongsberg XL The system must be in Pause mode, i.e. the Pause button must be lit, for these buttons to be operative. Note: It is possible to configure the jog direction, see Option->System setup. Incremental Jog Press this button to select Incremental jog mode.

  • Page 28: Pressurized Air System

    Kongsberg XL Variable Blow Back - adjust the air flow to a suitable level for the actual material. 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.

  • Page 29: Basic Operations

    Kongsberg XL 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 30: Reset Safety System

    Kongsberg XL Table Zero Sequence Press Start pushbutton to complete the Table Zero Sequence. The machine will move to the Selected Reference Point. Spindle Warm-up (milling toolhead only) Run Warm-up sequence by pressing this button in iPC. The spindle warning lamp (red) should flash shortly and then light constantly. This indicates that the spindle rotates.

  • Page 31: Continue After Safety Break

    Kongsberg XL 7.4. 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 32: Prepare For A Job

    Kongsberg XL 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 33 Kongsberg XL This position was not reachable for all tools and cameras (depending upon tool head). In order to run all tools properly, a limited work area was defined, using a separate Reference Point. In iPC For MultiCUT, MultiCUT HP, PowerHead and FlexiHead with i-Camera The Main Reference Point is defined to be in Main Zero point 2 in the figure above.

  • Page 34: Create Job

    Kongsberg XL The Main Reference Point is defined to be in Main Zero point 1 in the figure above. That means you can run your files as before, using the Main Reference Point as your Reference Point. 8.3. Create Job In My Jobs List, double-click a file.

  • Page 35: Speed Setting

    Kongsberg XL 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 8.6. Speed Setting Opened Job->Production Setup->Quality. Specify if this is a High Accuracy or a High Speed Job.

  • Page 36: Job Execution

    Kongsberg XL 8.9. 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. Press Pause to reset Safety System. Complete a Table Top Reference sequence to update Tool Height measurement.

  • Page 37: Make A Pen Plot

    Kongsberg XL 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. 8.11. Make a Pen Plot Follow the procedure for how to prepare for and execute a job.
  • Page 38 Kongsberg XL Measure all tools, started from GUI, procedure 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 •...
  • Page 39 Kongsberg XL • 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: Use this value to modify the height measured by the Measuring Pad.
  • Page 40 Kongsberg XL All Measuring Pad operations are cancelled by: • Press Close in the active dialog. • Press Pause on Operators Panel...

  • Page 41: How To Procedures, Advanced

    Kongsberg XL 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 42: Multi Pass Milling

    Kongsberg XL 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 milling bit diameter.

  • Page 43: Reverse Operation By Left And Right Rulers

    Kongsberg XL 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 44: Reverse Operation By Use Of Camera

    Kongsberg XL Workflow Step 1 - the sheet is aligned towards the Step 2 - the sheet flipped and aligned towards the Left Ruler. Right Ruler. The rest of the Job is completed. Reverse Operations are completed. A typical use of Reverse Operation is when you want to add a Crease line on the front side of a material that you normally prepare from the rear side.

  • Page 45: Reverse Operation In Combination With Step And Repeat

    Kongsberg XL 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. The function requires that the table is equipped with a Tool Head with Camera, and that the job has Regmarks.
  • Page 46 Kongsberg XL For more information, go here.

  • Page 47: System Setup

    Kongsberg XL 10. System Setup 10.1. Introduction This chapter will explain functions and parameters that are important for the to run properly. It is a supplement to the information available from the User Manual for i-cut Production Console. Examine each step carefully to ensure proper settings: One time adjustments completed at the factory The functions are included here as a reference.

  • Page 48: Adjust X1 To X2 Angle

    Kongsberg XL Set Table Top Reference 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.

  • Page 49: Set Ruler Position

    Kongsberg XL 10.4. Set Ruler Position Machine Connection->Machine Configuration->Installation_>Set Ruler Position 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.

  • Page 50: Reference Points And Coordinate System

    Kongsberg XL Procedure: 1. If the table is equipped with a Conveyor Belt, move the belt junction away from the table surface. 2. Execute the Map Table Top function. 3. Follow the instructions given by the wizard. 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.
  • Page 51 Kongsberg XL User Defined Reference Points You can specify User Defined Reference Points. User Defined Reference Points are used if you want your job positioned in a fixed position on the table (Rx), but not in the Main Reference Point (R).

  • Page 52: Jog Settings

    Kongsberg XL 10.9. 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. Opened Job->Layers->Edit Layer->Acceleration Modify acceleration for this particular Job.

  • Page 53: Milling Unit Setup

    Kongsberg XL 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.   The Tool Height is measured in current position and the reference to the table top surface is updated.

  • Page 54: Board Size

    Kongsberg XL 10.13. Board Size Not implemented yet...

  • Page 55: Tool Configuration And Adjustment

    Kongsberg XL 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 56: Tool Height Calibration

    Kongsberg XL See the description of each Tool Type for more specific information: 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.
  • Page 57 Kongsberg XL 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 58: Rotation Adjustment (For Rotating Tools)

    Kongsberg XL 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 59: Center Offset Adjustment

    Kongsberg XL 9. Press Tool Override Down once more to lower the Tool again. 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.

  • Page 60: Manual Adjustment Of Center Offset And Angle

    Kongsberg XL 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 61: Maintain Tool List (More

    Kongsberg XL 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 62 Kongsberg XL • Add new Tools • Add tools that fails during Automatic Tool Detection The Tool is added to the Tool List.

  • Page 63: Tooling System

    Kongsberg XL 12. Tooling System 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 <...

  • Page 64: Tool Heads Available, Overview

    Kongsberg XL 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 65: Tool Head Mount / Dismount

    Kongsberg XL 12.4. Tool Head mount / dismount >> >> Be careful not to apply too much force when fixing the signal cables. 12.5. FlexiHead Tool Head Description 1. Tool positions 1, 2, 3 with locking knobs 2. Outlet for Reciprocating Knife motor 3.

  • Page 66: Powerhead

    Kongsberg XL Replace a Tool Insert Observe the alignment pins Press the locking knob down Tool Adjustments, FlexiHead Tool Height Correct tool height relative to table top Lag Setting Tool Rotation Adjust tool angle tangential to moving direction Center Offset...

  • Page 67: Ø150 Mm Crease Wheel

    Kongsberg XL 3. Tool position 3 4. Laser Pointer 5. Measuring foot / material hold down foot 6. Electrical connection, reciprocating motor Tool Adjustments, PowerHead Tool Height Correct tool height relative to table top Lag Setting The lag value depends upon the blade adapter. Nominal value is 0 mm.

  • Page 68: Crease Adapter Ø26 Mm

    Kongsberg XL The additional pressure, combined with the large frontal area of the big wheel enables excellent crease quality in heavy-duty corrugated board and even permits creasing board with high recycle content without breaking the liner. A broad range of wheels with different shapes is available.

  • Page 69: Perforation Wheel Ø60 Mm

    Kongsberg XL 12.6.3. Perforation Wheel ø60 mm Use Perforation Wheel to prepare perforation lines at high speed. Suitable for corrugated board up to C flute (4 mm/0.16 in.). Perforation Wheel assembly Parts in assembly Ensure the path is clean.

  • Page 70: Hd Knife Tool

    Kongsberg XL Fix cover properly. Push / pull the perforation wheel in / out from the adapter. Tool Adjustment For this tool, complete the following adjustments: Adjustment Description Tool Height Measured automatically, possible to add an Offset Value. Lag Setting The Lag value depends upon the Blade Adapter.

  • Page 71: V-Notch Knife

    Kongsberg XL The HD Knife Tool is inserted in the HD crease tool position. The tool is adjusted and operates as an ordinary knife tool.   Knife Blade correctly positioned inside the The HD Knife Tool is ready with the Knife Blade mounted.
  • Page 72 Kongsberg XL How to insert / remove V-notch Knife Turn the V-notch Knife (A) correctly to fit the Both latch pins are used for the V-notch alignment pin (B). Knife. How to replace a Knife Blade This picture shows how the Knife Blade is 1.
  • Page 73 Kongsberg XL • The adjustment depends upon the actual material due to weight, structure and thickness. For optimal result, a fine tuning of the adjustments in the actual material should be carried out. Tool Height Correct tool height relative to table top Lag Setting Nominal value is 0-7 mm.
  • Page 74 Kongsberg XL V-notch cut direction The blade angle and the cut direction must be taken into account when cut jobs are prepared.   The arrow indicates the cut direction.     Different angles A wide range of V-notch knives is available, providing different knife angles, v: 15 , 22.5...
  • Page 75 Kongsberg XL Note: V-notch Knife Adapters are available for different knife angles: 15 , 22.5 , 30 , 45 . There is also a VariAngle unit available 47.5 for cutting any angle from -2 to 60 (release Q3 2020). In this chapter, a 45 knife angle is discussed.
  • Page 76 Kongsberg XL Crease This is the default mode. Width Offset Width Offset is used to adjust the width between the two cut lines along and across flute when Crease is selected. Waste Cut Waste Cut adds a third cut line to ease...

  • Page 77: Bevel Knife 45

    Kongsberg XL • Adjust the cutting width (W) by the adjustment parameter Width Offset. Nominally, the width of the cut has to be increased by Width Offset = - 2 x bottom liner thickness. • Width Offset limitations: -50 mm < Width Offset < +10 mm / -2 in < Width Offset < +0.4 in.

  • Page 78: Foamhead

    Kongsberg XL Note: On XL, this tool will reduce the work area by approximate 25 mm / 1 in. in some axes. 12.7. FoamHead Tool Head Description 1. Height sensor 2. Knife adapter 3. Material hold down wheels. Operator protection.
  • Page 79 Kongsberg XL Cutting quality To obtain best quality when cutting details, as small circles, we recommend: • Reduce the cutting speed (from Job Setup) • Cut in two or three passes, each pass going a step deeper (Multi pass). How to replace a Knife Blade A set of knife protection handles are available.

  • Page 80: Multicut

    Kongsberg XL • Your foam material is too soft for the measuring system. • The surface of your material is un-even. When the Disable Material Thickness Measurement function is enabled, the following rules applies: • Depth is referenced from bottom (top of cutting underlay).
  • Page 81 Kongsberg XL 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 82: Tool Head Description

    Kongsberg XL 12.8.2. Tool Head description 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.

  • Page 83: Safety Issues

    Kongsberg XL 5. Air clean button to help remove contamination. 6. Locking screw for the suction house. This screw is used when you want to lock the suction house in a position. Note: When in lower position, the house should be free to move up / down.
  • Page 84 Kongsberg XL • Be aware the risk of suction house clogging. • Milling MDF or other fine dust materials requires extra attention in order to keep the vacuum cleaner filter clean. Vacuum cleaner full • Follow the Vacuum Cleaner filling level carefully.

  • Page 85: Precautions

    Kongsberg XL Spindle speed Never use speeds higher than recommended by the bit supplier. Special care should be taken when using bits with cutting diameter larger than shank diameter. Milling bits Milling bits are very sharp – handle with care.
  • Page 86 Kongsberg XL Supervision of the milling spindle power 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. Too high Spindle Power consumption indicates critical conditions for the motor and immediate actions should be taken: 1.
  • Page 87 Kongsberg XL 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 88 Kongsberg XL 5. Follow procedures strictly: Chuck Change and Cleaning on page 95. 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.

  • Page 89: Milling Advice

    Kongsberg XL 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 house and suction tube clogging. 12.8.5. Milling advice Follow this advice for obtaining the best possible milling results.
  • Page 90 Kongsberg XL 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 91 Kongsberg XL Milling bit edges are brittle. Never let bits touch each other, or other hard surfaces. Always store in proper container. 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.

  • Page 92: Bits And Bit Change

    Kongsberg XL Number of passes in thick materials The Number of Passes depends on Material Type, Milling Depth and Bit Diameter. Use a Pass Depth that makes the groove free of chips, normally that is a depth equal to the Milling Diameter.
  • Page 93 Kongsberg XL Lock the house in its up position. Observe that the milling bit is not rotating. 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.
  • Page 94 Kongsberg XL Regularly, perform a Chuck cleaning, following the dedicated procedure; Chuck Change and Cleaning on page 95. Note: Never use Compressed Air for cleaning. Using Sleeve Adjustment Tool 34054510 ADJUSTMENT SLEEVE MULTICUT 20 34038406 ADJUSTMENT SLEEVE MULTICUT 28 Sleeve Adjustment Tools are available in two versions, with different depths.

  • Page 95: Chuck Change And Cleaning

    Kongsberg XL If a bit is stuck If a Milling Bit is stuck in the chuck, the probable cause is low air pressure. To release a Milling Bit from the chuck, a pressure of 7 bar is required. If necessary, check the Pressurized Air Regulator Valve, or the Pressurized Air source.  ...
  • Page 96 Kongsberg XL 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 97 Kongsberg XL 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. Use the Taper Brush to clean the Taper. Push the Air Clean Button to help remove contamination.
  • Page 98 Torque up the chuck by hand, using the Chuck Tool with a Dummy Bit. Hold the rotor with the 17 mm key. Close the chuck on a Dummy Bit. Chuck Maintenance Kits are available in the Esko Store on www.esko.com.

  • Page 99: 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. 12.8.9. 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 100: False Air Valve

    Kongsberg XL Balanced Bits Bits with balanced surface should have a clamping length f of min. 20 mm/0.8 inches. Maximum balancing length g is 12 mm/0.5 inches. 12.8.10. False Air valve MultiCUT is equipped with a False Air Valve. When milling small parts, use the False Air Valve to reduce the suction force.
  • Page 101 Kongsberg XL When properly adjusted, the milling bit should barely touch the top surface of the material.     12.8.12. Table Top and Height Adjustment The following rules apply when adjusting MultiCUT/MultiCUT-HP T = Cutting table, C = Cutting underlay Map Table Top function is carried out on top of the Cutting underlay.

  • Page 102: Miscellaneous

    Kongsberg XL 12.8.13. Miscellaneous Warm Up Machine Panel Toolbar->Warm Up To protect the Spindle, mandatory Warm Up is implemented.   If the Spindle has been inactive for 8 hours or more, a 3 min. Warm Up is required. If the Spindle has been inactive for 4 weeks or more, an extended sequence is required, called Run In.

  • Page 103: Chiller No 1 (Blue Top) For Multicut-Hp

    Kongsberg XL 12.9. Chiller no 1 (blue top) for MultiCUT-HP 12.9.1. Introduction This is chiller 1, replaced in October 2016 by a new model named chiller2016. Flow Measurement During operation, check the water flow level displayed on the chiller meter.

  • Page 104: Chiller, Error Conditions

    Kongsberg XL 12.9.2. Chiller, Error Conditions One common error signal is routed from the Chiller system to the inverter and further into the control system. The following error conditions are monitored: • Temperature out of range (high and low) • Liquid flow too low (less than 0.5 l/min). The signal is 1 minute delayed.
  • Page 105 Kongsberg XL 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 106: Chiller 2016 / Chiller 2020 For Multicut-Hp

    Kongsberg XL Program Temperature range Temperature range Hysteresis from ( to ( Factory Setting Correct factory setting is Program = 5 and temperature = 26 oC (Chiller with heater). 12.10. Chiller 2016 / Chiller 2020 for MultiCUT-HP 12.10.1. Introduction 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.

  • Page 107: Startup

    Kongsberg XL 12.10.2. 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 108: Measuring Foot

    Kongsberg XL   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 109: Laser Pointer

    Kongsberg XL 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 110: X-Pad

    Kongsberg XL 12.13. X-Pad 12.13.1. 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 111: Tool Depth And X-Pad

    Kongsberg XL • Pause button light is off. 12.13.2. 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 112: Tool Inserts

    Kongsberg XL 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 113: Bevel Knife

    Kongsberg XL Parameter Description Tool Height The tool tip should touch the material surface. Center Offset Adjust tool sideways until centered. Tool Offset Adjust offset relative to laser pointer. For more information about how to run the adjustment wizards, see Tool Configuration.

  • Page 114: Bevel Knife U20

    Kongsberg XL 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 115 Kongsberg XL 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 116 Kongsberg XL 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 117 Kongsberg XL If the Laser Spot is offset from the sphere, jog the tool head until the Laser Spot is placed exactly on top of the sphere. Click Finish and close the remaining tool adjustment dialogs. Configure Tool Menu Bar->Advanced->Configure Tools...
  • Page 118 Kongsberg XL 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 119: Corruspeed Knife

    Kongsberg XL 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 120 Kongsberg XL During processing, the corrugated material is partly crushed by the foot. The result is: • You can run at high speed. • The risk for material tear is significantly reduced. Foot pressure adjustment Material crushing depends upon two...

  • Page 121: Tool Adjustment

    Kongsberg XL 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 Observe the alignment pins. After a blade change, the tool depth should be checked again.

  • Page 122: Crease Tool

    Kongsberg XL 13.6. Crease Tool Crease Tool The Crease Tool is a multipurpose tool allowing a wide range of creasing wheels. Lag is nominal 0 mm. Replace crease wheel Push the wheel into position   13.6.1. Tool adjustment For this tool, complete the following adjustments:...

  • Page 123: Crease Tool, 60 Mm

    Kongsberg XL Parameter Description Tool Offset Adjust offset relative to Laser Pointer. For more information about how to run the adjustment wizards, see Tool Configuration. 13.7. Crease Tool, 60 mm Use the ø60 mm Crease Tool to avoid cracking the liner.

  • Page 124: Drill Tools

    Kongsberg XL 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 125: Reboard Drill Tool

    Kongsberg XL 13.8.2. Reboard Drill Tool Reboard Drill Tool is a tool insert for a standard XL tool position. 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).

  • Page 126: Tool Adjustment

    Kongsberg XL 13.8.4. Tool Adjustment For this tool, complete the following adjustments: Parameter Description Tool Height The tool tip should touch the material surface. Tool Offset Adjust offset relative to laser pointer. For more information about how to run the adjustment wizards, see Tool Configuration.

  • Page 127: Ink Tool

    Kongsberg XL Lag adjustments for Foam Knife The lag for the Foam Knife tool should be 2.5mm (0.1") How to replace a Knife Blade Static Knife. Follow instructions for 13.10. Ink Tool Two ink tool models are available; Liquid Ink Tool and Fibertip Tool.

  • Page 128: Fibertip Tool

    Kongsberg XL Ink tool assembly 13.10.2. Fibertip Tool Fibertip Tool is for ink drawing. The tool is prepared for Staedtler Lumocolor insert. Fibertip tool assembly 13.10.3. Tool adjustment For this tool, complete the following adjustments:...

  • Page 129: Kisscut

    Kongsberg XL 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 130 Kongsberg XL Replace Knife Blade This figure shows how the Knife Blade is fixed A special hand tool is available as an aid when inside the KissCut knife tool. replacing knives. Use this hand tool when removing and inserting knives into the tool.

  • Page 131: Microcut

    Kongsberg XL Foot solution Normally, the KissCut knife tool is used without the foot mounted. When the foot is mounted, the cutting depth d is controlled by the adjustable screw S. For this tool, complete the following adjustments: Parameter Description...
  • Page 132 Kongsberg XL How to set Cutting Depth • When inserting a new Knife Blade, align the tip of the knife with the sliding sleeve and zero the depth meter (A). • Then adjust the micrometer screw (Starret micrometer (218)) until desired depth is displayed (B).

  • Page 133: Psaligraphy Knife

    Kongsberg XL Parameter 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 Tool Configuration. 13.13. Psaligraphy Knife Note: iPC version 2.0 or higher is required to run this tool.

  • Page 134: Tool Adjustment

    Kongsberg XL 13.13.1. 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 135: Reciprocating Knife

    Kongsberg XL Tool Adjustment Use the standard adjustment wizards when adjusting the knife. We recommend using a sheet of corrugated material, 5-6 mm / 0.2 inch, when executing the wizards. Parameter Description Tool Height The tool tip should touch the material surface.
  • Page 136 Kongsberg XL MP HF Knife Running with 12000 RPM and amplitude +/- 0.6 mm (0.024 inches), this tool is recommended for more demanding corrugated materials. Note: Hearing protection is recommended when working with this tool. Common to both models: • To reduce material tear, a foot is available.

  • Page 137: Tool Adjustment

    Kongsberg XL Extreme care should be taken when inserting the knife foot again. Keep fingers away from knife as illustrated at left. 13.15.1. Tool adjustment For this tool, complete the following adjustments: Parameter Description Tool Height The tool tip should touch the material surface.
  • Page 138 Kongsberg XL Insert / remove knife blade Ensure the blade is correctly aligned. Use a 3 mm Allen Key to fix / loosen the knife blade. After a blade change, the tool depth should be checked again. Tool Adjustment Use the standard adjustment wizards when adjusting the knife.

  • Page 139: Rotacut

    Kongsberg XL 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 140 Kongsberg XL 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 141 Kongsberg XL 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 142: Static Knife

    Kongsberg XL 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 143: Tool Adjustment

    Kongsberg XL Knife direction The locking screw will always point towards The locking screw will always point towards the cutting direction the 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 144: Vixx Knife Tool, Mounting/Adjustment

    Kongsberg XL 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 145: Vi45 Knife Tool

    Kongsberg XL Define the depth of the bevel cut in the Layer Setup. Normally, the cut should extend down to just above the bottom liner. After a blade change, the tool depth should be checked again. About tool adjustment For the VIxx Knife Tool, we recommend the manual procedures for tool rotation and centre offset adjustment.
  • Page 146 Kongsberg XL 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 147: Vi45-10/12 Knife Tool

    Kongsberg XL 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.   Remember that you should look at the bottom side of the material for correct alignment.  ...
  • Page 148 Kongsberg XL Observe Alignment Pin orientation. Keep the knife adapter in this position while you turn the tool shaft… …in order to lock the tool adapter in its position. How to set the cutting depth of the VIxx Knife Tool The default cutting depth is to cut through the entire material.
  • Page 149 Kongsberg XL Note: On XL, this tool will reduce the work area by approximate 25 mm / 1 in. in some axes.

  • Page 150: Maintenance

    Kongsberg XL 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 151: Fuse Replacement

    Kongsberg XL 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 Note: Some equipment described might be optional. 15.1. MPU fuses MPU Location Note: MPU location is model dependent.

  • Page 152: X1 Fuses

    Kongsberg XL 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 153: Y/Z Fuses

    Kongsberg XL X2 Amplifier Location 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 154: Tool Rotation/Reciprocating Knife Fuses

    Kongsberg XL 3 – Z-axis motor 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 155: Sound Insulating Box, Circuit Breaker For Fan

    Kongsberg XL 15.6. Sound Insulating Box, Circuit Breaker for fan A separate circuit breaker for the fan is introduced. For proper operation, ensure the ON/OFF switch A is in ON position. Correct fuse setting for the fan is B = 1.0 A.

  • Page 156: Vacuum Cleaner

    Kongsberg XL 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 157 Kongsberg XL 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 158: 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 159 Kongsberg XL 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 160 Kongsberg XL 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 161: Compact Vacuum Cleaner

    Kongsberg XL 16.3. Compact Vacuum Cleaner 16.3.1. 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 162 Kongsberg XL 5. Lift and turn the container to release it from the fixture. 6. Empty the container.

  • Page 163: Install Software

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

  • Page 164: 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 165: Tools

    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 Milling: “Communication error: Failed to connect to milling controller. Try again, if the problem persists, check COM-Port setting and milling controller hardware”...

  • Page 166: Ipc

    Kongsberg XL Check vacuum zones. Are all necessary zones open? You can close non-covered areas to strengthen the vacuum. Check the force of the vacuum cleaner. It happens the vacuum cleaner is heightening the milling carpets. Try to adjust the force by using the regulator on the spindle / vacuum cleaner.

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