Page 1 KONGSBERG XP — User Manual 12 - 2024|XP...
Page 2: Table Of Contents
Kongsberg XP User Manual CONTENTS 1 Preface ..........................8 C o n t e n t s 2 Change Record ........................9 3 Introduction ........................11 3.1. Welcome ............................. 11 3.2. Where to find information ......................11 4 Using this manual ......................13 4.1.
Page 3 Kongsberg XP User Manual 6.3. Operators Panel .......................... 33 6.4. Pressurized air system ........................ 35 6.5. Application Programs Available ....................36 7 Basic Operations ........................ 37 7.1. Introduction ..........................37 7.2. Power On Sequence ........................37 7.3. Reset Safety System ........................38 7.4.
Page 4 Kongsberg XP User Manual 10.13. Milling Unit Setup ........................64 10.14. Conveyor Belt Control ......................... 64 10.14.1. Split Sheet Feed ......................65 10.14.2. Sheet Feed Correction ....................65 10.15. Board Size ........................... 65 11 Tool Configuration and Adjustment ..................66 11.1.
Page 5 Kongsberg XP User Manual 12.10.2. Tool Head description ....................119 12.10.3. Safety issues ......................120 12.10.4. Precautions ......................123 12.10.5. Milling advice ......................126 12.10.6. Cleaner Device ......................129 12.10.7. Bits and Bit Change ....................129 12.10.8. Chuck Change and Cleaning ..................132 12.10.9.
Page 6 Kongsberg XP User Manual 13.5. Maintenance, External Equipment ................... 181 13.6. Maintenance, Take Up Unit ...................... 182 13.6.1. General ........................182 13.6.2. Spare Parts ....................... 182 14 Fuse Replacement ......................183 14.1. MPU fuses ..........................183 14.2. X1 .............................. 184 14.3.
Page 7 Kongsberg XP User Manual 20 Frequently Asked Questions ..................... 218 20.1. Machine ............................ 218 20.2. Tools ............................219 20.3. iPC ............................. 219...
Page 8: Preface
Kongsberg XP running i-cut Production Console NOTE: We remind you that only the Kongsberg Staff, or persons having received appropriate training, are allowed to handle, manipulate or do repairs on the system. NOTE: Original instructions are in English. Instructions in other languages are translations of original instructions.
Page 9: Change Record
+ misc. 19.09.2018 Section for Underside Camera added. Reverse operation by use of camera added. 30.11.2018 2nd Fast Tool Enabler for Cx (and XP) and misc. 28.02.2019 Safety precautions updated. Feeder/Stacker procedures updated. 10.04.2019 2nd Fast Tool Enabler renamed to Fast Tool Adapter.
Page 10 Warning sign "Sharp knives" added 27.10.2020 VariAngle unit included 06.11.2020 Work areas for MultiZone Production updated 19.11.2021 New issue for Kongsberg PCS Cleaning of RotaCut knife tool added 18.02.2022 Maintenance iBF, iMS and USC updated. Prepared for translation. 31.03.2022 Feeder Operator Controls updated 24.05.2022...
Page 11: Introduction
User Manual for i-cut Production Console. This manual is aimed for operators of Kongsberg Cutting Tables and people preparing files for such equipment. Another source for information is the manual: Get the best out of iPC.
Page 12 Kongsberg XP User Manual Title Target personnel Media Language Purpose Site preparation Customer English and local How to prepare for manual installation. User manual for Customer English and local User Manual cutting table, incl. maintenance User manual for Customer English and local...
Page 13: Using This Manual
Kongsberg XP User Manual USING THIS MANUAL 4.1. Main Sections The manual is divided into the following Main Sections: Safety Regulations on page 16 • All safety related issues are discussed. System Description on page 32 • This chapter provides basic knowledge about the machine.
Page 14: Name Styles And Symbols
Kongsberg XP User Manual 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 15: Local Languages
Kongsberg XP User Manual 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. 15 |...
Page 16: 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 17: 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 Kongsberg service engineer as part of the system installation. The training covers: •...
Page 18 Non-intended use may cause: • Health hazards and injuries. • Damage to the system. • Incorrect functionality. • Damage to work materials. NOTE: Kongsberg is not liable for any damage resulting from such non-intended use. 18 |...
Page 19: Warning Sign Explanation
Do not open cover on either MPU or vacuum pump before mains is disconnected from cutting tableand vacuum pump. NOTE: KongsbergUltimate, C series/XP and X series have different electrical structures, and therefore these warnings are different for the three machine series.
Page 20 Kongsberg XP User Manual General warning Milling tools Milling tools require skill, and must be run by QUALIFIED OPERATORS ONLY This is based on • Safety issues • Protection of the equipment • Taking care of expensive materials Hand Injury Potential areas with a risk of being injured to the hand are marked with Hand Injury sign.
Page 21: Attention Areas
Kongsberg XP User Manual Remove bit/blade before tool Some tools need for safety reason that the bit or blade is removed before the tool is dismounted. These tools are marked with this label. Hearing Protection The Hearing Protection symbol indicates areas where the use of hearing protection is recommended.
Page 22: Mains Power Disconnection
In addition, turn off the main power switch. Note: A lockable on/off disconnection device on the power line may be required by local regulations, but is part of the site preparation, site owner’s responsibility, not included in the Kongsberg system delivery unless agreed. 5.6.2. ...
Page 23: Loose Clothing
Kongsberg XP User Manual 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 24: Milling Stop Time
Kongsberg XP User Manual 5.6.6. 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 25: Emergency Stop Buttons
Kongsberg XP User Manual 5.7.2. Emergency stop buttons Switch positions OUT - Normal operation enabled IN - Emergency stop active Servo power to the machine is switched off 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.
Page 26: Yellow/Black Floor Tape
Kongsberg XP User Manual Observe that servo power is switched on. Press Start to continue. 5.7.3. Yellow/black floor tape The yellow/black tape indicates the hazard attention area. This area is restricted to operators and other trained personnel. Do not enter the hazardous area during operation unless interaction with the machine is required.
Page 27: Milling Warning Lamp
Constantly lit indicates running. Flashing indicates starting or stopping. Before touching the milling bit, always ensure also by visual inspection that the bit has come to a complete standstill. 5.8. Protective equipment For the operators, Kongsberg recommends the following protective equipment: 27 |...
Page 28: 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 performed by authorized personnel only. Contact Kongsberg PCS Support. 5.10. Check before operation Before operating the equipment, check the following: • Electrical cables without damage •...
Page 29: Residual Risks
Kongsberg XP User Manual 5.11. Residual risks Despite all safety protection means incorporated in this machine, there are some residual safety risks to be aware of: Below traverse end The lower part of the traverse end is un-protected. Actions: •...
Page 30 Kongsberg XP User Manual Inside cable chain There is a risk for squeezing between the cable chain and the table frame. Actions: • Stay out of this area while the machine is operating. Under the lower DynaGuard light beam It is possible to reach under the lower DynaGuard light beam into tool hazard areas.
Page 31 Kongsberg XP User Manual Broken knife blade stuck in processed material Be aware that broken knife blades can be stuck in the finished processed material. When offloading these materials, there is a risk of interaction with sharp objects. Touching the milling bit while rotating Stop time of the milling spindle is up to 4 seconds.
Page 32: System Description
Kongsberg XP User Manual 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 33: Main Power Switch
Kongsberg XP User Manual X1 - X1 end of traverse 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.
Page 34 Kongsberg XP User Manual 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. Provides material hold down.
Page 35: Pressurized Air System
Kongsberg XP User Manual Jog buttons Press the Jog buttons to move the tool head in the desired direction. 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.
Page 36: Application Programs Available
Kongsberg XP User Manual The compressed air input is connected to a combined Pressure Regulator Valve/Water Trap. Wall outlet - Wall outlet A - Air supply tube R - Pressure regulator valve P - Pressure gauge W - Water trap T - Air tube For details regarding air supply requirements, see Site Preparation Manual.
Page 37: Basic Operations
Kongsberg XP User Manual 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 38: Reset Safety System
Kongsberg XP User Manual 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 39: Continue After Safety Break
Kongsberg XP User Manual Exit iPC Close the iPC application. Note: Failing to do this might result in table to not operate correctly on restart. Table Power Turn Table Power off using the Main Power Switch. Note: After power off, wait minimum 5 sec. before the system is switched on again.
Page 40: Prepare For A Job
Kongsberg XP User Manual 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 41: Production Setup
Kongsberg XP User Manual 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. ...
Page 42: Execute A Job
Kongsberg XP User Manual 8.8. Execute a job 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 43: Make A Pen Plot
Kongsberg XP User Manual Recommended tooling is described in Kongsberg Tooling Guide. Note:Milling Jobs should be executed in High Quality mode. 8.11. Make a Pen Plot Pen Plot without Registration Marks is straight forward following the procedure described in the...
Page 44: How To Procedures, Advanced
Kongsberg XP User Manual 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 -> Select Vacuum Zones. Select or deselect vacuum zones or use Intelligent vacuum control.
Page 45: Cutting Thick Materials
Kongsberg XP User Manual 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 46: Job Including Reverse Operation
Kongsberg XP User Manual 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 47 Kongsberg XP User Manual 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 allows reverse side operation. Turned off. Status 2: Selected tool allows reverse side operation. Turned on.
Page 48: Reverse Operation By Left And Right Rulers
Kongsberg XP User Manual The symbols assume that the table is viewed from the front. 9.5.1. Reverse Operation by Left and Right Rulers Workflow Step 1 - the sheet is aligned towards the Right Step 2 - the sheet flipped and aligned towards the Ruler.
Page 49: Reverse Operation By Use Of Camera
Kongsberg XP User Manual 9.5.2. Reverse Operation by use of camera Workflow Step 2 - the sheet is flipped (turned or tumbled), Step 1 - Regmarks and corners are read by the camera. and corners are read by the camera.
Page 50: Work With Different Reference Point Settings
Introduction In user manual for i-cut Production Console, general information about MultiZone Production is available. In this section, XP specific issues are described. MZP Panel Each work zone is equipped with a panel that makes it possible to run the complete MultiZone Production sequence from the table.
Page 51 Kongsberg XP User Manual • 1 - Ready lamp • 2 - Ready button • 3 - Vacuum on button • 4 - Vacuum lamp Vacuum Zones Vacuum Zone Configuration on page 62 MultiZones The illustration shows the most actual zones available for MultiZone Production.
Page 52 Kongsberg XP User Manual XP20 XP24 XP44 Work area 1680x1600 1680x3200 2210x3200 mm/in 66x63 66x126 87x126 Work area, MultiZone Production, 1680x1425 2210x1425 standard tabletop 66x56.1 87x56.1 mm/in [To be updated] 52 |...
Page 53: Multizone, Workflow
Kongsberg XP User Manual 9.7.1. MultiZone, workflow - Recommended material flow direction. - 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 continuous 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 54: System Setup
SYSTEM SETUP 10.1. Introduction and overview This section will explain functions and parameters that are important for Kongsberg XP to run properly. It is a supplement to the information available from the user manual for i-cut Production Console (iPC). Examine each step carefully to ensure proper settings: One time adjustments completed at the factory The functions are included here as a reference.
Page 55: Register Table Size
10.3. Register Table Size Note: This taks should be performed by qualified Kongsberg service personnel only. Machine Connection->Machine Configuration->Installation_>Register Table Size This wizard moves the Tool Head from edge to edge of the Cutting Table in order to measure the table size.
Page 56: Set Ruler Position
Kongsberg XP User Manual Machine Connection->Machine Configuration->Installation_>Adjust Measuring Station Position Use this wizard to calibrate the position of the Measuring Station to the system. Typical use is after maintenance or repair. Procedure: Press the Adjust Measuring Station Position button. Follow the instruction given by the wizard.
Page 57: Map Table Top Surface
Kongsberg XP User Manual 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 58: Calibrate Foot On Measuring Station
Kongsberg XP User Manual At that time, a (MDF) plate was used as milling underlay. The plate was milled in order to make a perfectly compensated underlay for milling. As this function is not used anymore, and conveyor belts break the 5 mm limit, iPC now always compensate based on table top mapping.
Page 59 Kongsberg XP User Manual 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 60: Jog Settings
Kongsberg XP User Manual Position the Laser Pointer in the position where you want your Panel Reference Point. 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 61 Kongsberg XP User Manual Incremental Jog Step Size The size of the Incremental Jog movements can be customized. Machine Connection->Machine Configuration->Setup->Incremental Jog Specify Step Size to be used. Jog Directions Machine Connection->Machine Configuration->HW configuration->Operator panel Specify operator panel position. This will define the jog directions for the buttons on the operator panel.
Page 62: Set Table Top Reference
Execute the Table Top Reference function. In the wizard, press OK to start measurement. 10.12. Vacuum Setup 10.12.1. Vacuum Zone Configuration Note: This taks should be performed by qualified Kongsberg service personnel only. Machine Connection->Machine Configuration->HW Configuration->Vacuum Setup 62 |...
Page 63 Kongsberg XP User Manual 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 64: Milling Unit Setup
Kongsberg XP User Manual Machine Zone Configuration Vacuum Configuration XP20 XP24 XP44 10.13. 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.
Page 65: Split Sheet Feed
Kongsberg XP User Manual Specify if the machine is equipped with Conveyor Belt. 10.14.1. Split Sheet Feed Sheet in Load Position Sheet Load, step 1 Sheet Load, step 2 In some occasions, the sheet unloaded from the cutting table can trigger the photo cell safety system.
Page 66: Tool Configuration And Adjustment
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. In addition, there are separate fixtures for Laser Pointer, Measuring Foot, Camera, Drill and Pen Tools:...
Page 67 Kongsberg XP User Manual L - Laser Pointer M - Measuring Foot P1 - P1 tool position, see table below C – Camera position P - Pen / Drill / Ink Tool holder position P2 - P2 tool position, see table below...
Page 68: Tool Names
Kongsberg XP User Manual Tool Type Available Tool Inserts Psaligraphy knife tool CorruSpeed knife tool Braille Tool Drill/Pen Holder Drill Tool, Ballpoint Pen, Ink Tool (Fibertip Yes (1) Tool) Laser pointer Yes (2) Measuring Foot Yes (2) Camera system Yes (2) This table shows correct position for the different tools.
Page 69: Adjust Active Tool
Kongsberg XP User Manual The identified tool is called Factory Tool Name The mounted tools are maintained by: Machine Connection->Tool Configuration Current tool configuration is displayed under Identified tools. When a new tool is inserted, it will be identified to the system automatically.
Page 70: Tool Head Camera Calibration
Kongsberg XP User Manual Before any adjustment, complete a Table Top Reference function. 11.4. Tool head Camera Calibration For tool headCamera Calibration, refer to section Camera Calibration in user manual for iPC. 11.5. Lag settings for rotating tools Machine Connection->Tool configuration->Adjust Active Tool->Lag Settings Follow instructions from the wizard.
Page 71 Kongsberg XP User Manual Lag settings dialog Run this wizard to obtain correct Knife Lag value. Follow the instructions in the dialog. Add the measured value to the displayed value. Circular Lag Circle quality is determined by a parameter called Circular Lag. The parameter value will vary depending upon the actual material.
Page 72: Tool Height Calibration
Adjust Tool Height is also available directly from the machine panel. Kongsberg XP is equipped with automatic Tool Height Calibration. Thus, the system will run without any manual height calibration. If you would like to add an offset to the measured height, use the Tool Height Calibration dialog: Select the Tool to be adjusted Press the Adjust Active Tool button to enter the wizard selection dialog.
Page 73: Manual Adjustment
Kongsberg XP User Manual Select Rotation adjustment. Follow the instructions given by the wizard, step by step. Repeat the procedure for all Tools mounted. Manual Adjustment Machine Connection->Tool configuration->Adjust Active Tool->Manual Adjustment of... Follow instructions from the wizard. Place an appropriate test material on the table, and switch Vacuum On.
Page 74: Tool Offset
Kongsberg XP User Manual will create a misleading offset in this wizard), and switch vacuum on. Select the Tool to be adjusted. Press the Adjust Active tool button to enter the wizard selection dialog. Select Center Offset Adjustment. Follow the instructions given by the wizard, step by step.
Page 75: Knife Angle Calibration
Kongsberg XP User Manual A cross is made by the Tool to be adjusted. The Laser Pointer is positioned in the center of the cross. If necessary, jog the Laser Spot into the center of the cross. Follow the instructions given by the wizard, step by step.
Page 76: Delete Tool
Kongsberg XP User Manual Ignore Automatic Tool Identification Ignore Automatic Tool Identification may be used when the Automatic Tool Detection fails, and manual tool selection is necessary. If Ignore Automatic Tool Identification is checked, Tool Setup remains unchanged after: •...
Page 77: Tooling System
Kongsberg XP User Manual 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 78: How To Replace A Tool
Kongsberg XP User Manual 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 79: Measuring Station
1 on & 2 off Tool 3 1 off & 2 on Tool 4 1 & 2 on Note: There are some restrictions, see Technical Manual for more information. 12.5. Measuring Station XP is equipped with a Measuring Station: 79 |...
Page 80 Kongsberg XP User Manual 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 81: Hdu - Heavy Duty Unit
Kongsberg XP User Manual 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 82: Tool Adjustment
Kongsberg XP User Manual 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: Adjustment Description Lag Setting The Lag value depends upon the Blade Adapter.
Page 83: V-Notch Knife Tool
Kongsberg XP User Manual 12.6.2. V-notch Knife Tool Description The V-notch Knife Tool mounted on a Heavy Duty Unit. 83 |...
Page 84 Kongsberg XP User Manual 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. 3 Insert the Cotter Pins. How to replace a Knife Blade...
Page 85 Kongsberg XP User Manual This picture shows how the Knife Blade is aligned using two Guide Pins (a and b) beneath the blade clamping. Loosen the two screws (b) of the Knife Blade clamping. Carefully remove the blade (a). Insert a new Knife Blade and make sure that it is aligned with the Guide Pins (c).
Page 86: V-Notch Knife Tools, Modes Of Operation
Kongsberg XP User Manual 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 and Adjustment on page 66...
Page 87 Kongsberg XP User Manual NOTE: V-notch Knife Adapters are available for different knife angles: 15 o , 22.5 o , 30 o , 45 o , 47.5 o . There is also a VariAngle unit available for cutting any angle from 0 to 60 In this chapter, a 45 o knife angle is discussed.
Page 88 Kongsberg XP User Manual V-notch Cut Performs a single angled cut 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...
Page 89 Kongsberg XP User Manual When the knife angle is 45 o and you cut through the material, the width of the cut is W = 2 x h. IMPORTANT: Achieving a perfect fold depends on multiple factors, including the width of the blade, the flute direction, and the characteristics of the material being cut.
Page 90: Hd Knife Tool
Kongsberg XP User Manual This illustration shows a typical use of Waste Cut function. The middle wall is not cut by (2) or (3), making the material impossible to fold. The Waste Cut function (1) cut the middle wall and you can fold the material nicely.
Page 91 Kongsberg XP User Manual Warning: Sharp tool This picture shows how the Knife Blade is aligned against two Guide Pins. Use these two screws to fix / release the Knife Blade. 91 |...
Page 92 Kongsberg XP User Manual 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 93: Crease Adapter
Perforation wheels with different pit to land ratios are suitable for multiple purposes in different materials. Before August 2019, Kongsberg’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 94 Kongsberg XP User Manual 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. Tool Adjustment For this tool, complete the following adjustments: 94 |...
Page 95: Bevel Knife 45
Kongsberg XP User Manual 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. Tool Height Measured automatically, as separate tool, possible to add an Offset Value.
Page 96 Kongsberg XP User Manual • 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.
Page 97: Foam Cutting Unit
Kongsberg XP User Manual 12.7. Foam Cutting Unit Description The Foam Cutting Unit is mounted onto the P1–position. DANGER: Be careful where to place the Foam Cutting Unit when not in use. If it is left on a table surface, the knife blade might be exposed, as the material hold down wheels moves up.
Page 98 Kongsberg XP User Manual How to replace a knife blade Loosen the fixing screw, replace the knife blade and fix it again. No additional adjustments are necessary, as the tool height is measured automatically. A set of knife protectors is available.
Page 99 Kongsberg XP User Manual Disable material thickness measurement Opened Job->Layers->Edit Layer. For the Foam Cutting Unit, the Disable Material Thickness Measurement function is available. Use this function if: • The foam material is too soft for the measuring system, or •...
Page 100: Dual Hdu - Dual Heavy Duty Unit
Kongsberg XP User Manual 12.8. Dual HDU - Dual Heavy Duty Unit P1.1 – Position 1 of the Dual HDU, equal to the standard HDU. P1 – P1 tool positions, see table below P1.4 – The secondary position of the Dual HDU (and thereby the 4th P2 –...
Page 101: Dual Hdu Hd Perf Position
Kongsberg XP User Manual P1.1 P1.4 Comments HD 30 Knife Cannot combine HD30 with 2nd tooling position V-notch inserts (all angles) Cannot combine V-notch with 2nd tooling position For detailed descriptions of the P1.1 tooling-inserts, see separate section for HDU – Heavy Duty Unit: •...
Page 102 Kongsberg XP User Manual Perforation Wheel mounting for the Dual HDU The Perforation Wheels are locked in place using a Locking screw when mounted in the HD Perf position. This is to ensure that the wheel is not pulled out when converting heavy materials.
Page 103: New Mounting Procedure For Hd Insert Tools
Kongsberg XP User Manual Tool Adjustment For this tooling position, 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 104 Kongsberg XP User Manual Insert the Locking Pin from one side until it snaps in place. No Cotter pin is needed from the other side. For HD inserts other than HDCrease, remember to use both pins. Note: Check that the pin is inserted all the way in.
Page 105 Kongsberg XP User Manual 105 |...
Page 106: Variangle Unit
Knife blade for cutting of thicker board The VariAngle Unit is a tool for position P1 on Ultimate and C/XP platforms. It is specially materials. There are different blade lengths that prepared to cut at different angles (also known as fit different adapters.
Page 107: Knife Blade Adapters
Kongsberg XP User Manual 12.9.3. Knife blade adapters The knife blade adapter comes in two versions; standard adapter for standard/long knife blades and an optional long adapter for short knife blades. The standard adapter can always be used; the long adapter gives better results in thin materials.
Page 108 Kongsberg XP User Manual The table describes the limitations for the two adapters, with regard to material thickness and notch angle: • Orange: Standard adapter with standard/long knife blades • Green: Long adapter with short knife blades. 6 mm / 0.24 in.
Page 109: Tool Adjustment
Kongsberg XP User Manual How to mount / dismount adapter with knife blade to the tool Adapters are fixed with a thumb screw. Loosen the screw and pull out the adapter. Note: For safety reason, always mount the tool to the machine before mounting adapter with knife blade.
Page 110: Basic Modes Of Operation
Kongsberg XP User Manual Adjustment Description Notch angleoffset This is for obtaining the correct notch angle. Tool Offset This is for aligning tool position with laser pointer or camera. 12.9.5. Basic modes of operation NOTE: A material thickness must always be defined when using the VariAngle Unit. Select an existing material from the Jobwindow, or create a new material with a thickness from Advanced ->...
Page 111 Kongsberg XP User Manual 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-notchCrease will perform two cuts facing each other independent on the specified cut direction.
Page 112: Workflows, Set-Up And Optimization
Kongsberg XP User Manual 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.
Page 113 Kongsberg XP User Manual 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 used, see Job including Reverse Operation. Knife Overcut The Knife Overcut function will add length to the start and/or end of all lines within a layer.
Page 114 Kongsberg XP User Manual 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 115 Kongsberg XP User Manual NOTE: Use caution when applying this function, as too much preloading might cause the knife blade to break or cut into the table top. Further, this setting is only suitable for cutting at an angle, not for 0 degrees cuts.
Page 116: Work Area Limitations
Kongsberg XP User Manual 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 117: Material Lift
If small deviations are detected, the tool will automatically perform a recalibration. Check that the tool is properly mounted and run a manual Table Zero Sequence. If the problem persists, then contact Kongsberg PCS Support. 12.10. HPMU - High Power Milling Unit 12.10.1. ...
Page 118 Kongsberg XP User Manual Spindle motor Power rating (max) 3 kW Cooling system Liquid cooling Shank size (max) 8 mm RPM (max) 60.000 Tool change Pneumatic HPMU chucks Different chucks are available from the webshop: https://kongsbergstore.com Replacing a chuck Replacing a chuck is described in detail in...
Page 119: Tool Head Description
Kongsberg XP User Manual 12.10.2. Tool Head description Suction House with brush for chip removal. During normal operation, the house is in down position. When changing bit, the house should be locked in its upper position. Air Blow adjustment. Air Blow is used for milling bit cooling and to ease chip removal.
Page 120: Safety Issues
Kongsberg XP User Manual HPMU Park Position A HPMU Park Position is available on the gallows stand. Use the park position for safe HPMU Tool Head storage. Note: For safety reasons, always insert a Dummy Bit when parking. Chiller / HPMU start up time Depending upon the environmental temperature, the Chiller needs some start-up time after Power On before it is ready to operate.
Page 121: Ejection Of Parts
Kongsberg XP User Manual It is a good rule to keep an eye on a milling job being executed. Pay special attention to: • Do not leave the machine running if the vacuum cleaner can be over-filled. This might cause damage, or in worst case a fire if the suction house is clogged.
Page 122: Hearing Protection
Kongsberg XP User Manual Always use eye protection when working with milling. Hearing protection The noise generated by milling varies with the material being processed and running parameters. Hearing protection is highly recommended and may even be mandatory. Spindle speed Never use speeds higher than recommended by the bit supplier.
Page 123: Precautions
Kongsberg XP User Manual Keep the table and material surfaces clean, free from obstacles. 12.10.4. Precautions Follow these precautions to take care of the milling spindle, which is a high precision unit, that can get damaged by careless use. Supervision of the milling spindle power Machine Panel->Spindle Power...
Page 124 Kongsberg XP User Manual For best performance and minimum wear, do not let the bit extend out from the chuck more than necessary. Use bits with short cutting lengths for thin materials. Chuck Open/Close valve operation Never operate the Chuck Open/Close Valve while the Spindle is running.
Page 125 Kongsberg XP User Manual Maintain Bit Clamping Un-proper bit clamping may cause the bit to slip in the chuck and damage the Table Top. Keep the bit shaft clean. Avoid greasy fingers. Clean the bit shaft with acetone if necessary, but use only dry cotton tips on the chuck.
Page 126: Milling Advice
Kongsberg XP User Manual Empty Vacuum Cleaner in time Do not leave the machine running if the Vacuum Cleaner can be over-filled. This might cause damage, or in worst case a fire due to the hot milling bit in contact with debris in the suction system.
Page 127 Kongsberg XP User Manual 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 128 Kongsberg XP User Manual Acrylic Bits or Multi Purpose Bits Acrylic Bits (A) are polished, extra sharp for acrylic, wood etc. Multi Purpose Bits (MP) have a higher wear resistance, and are suitable for aluface, plastics, MDF, plywood, wood etc.
Page 129: Cleaner Device
Kongsberg XP User Manual 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 129 |...
Page 130 Kongsberg XP User Manual Ensure the Spindle is not running, and that the red light is off. Mind the sharp bit, and move the Suction House Lock the house in its up position. Observe that the milling bit is not rotating, by visual inspection.
Page 131 Kongsberg XP User Manual Release the Lock to allow the Suction House moving down to its down position. Regularly, perform a Chuck cleaning, following the dedicated procedure; Chuck Change and Cleaning on page 132 NOTE: Never use Compressed Air for cleaning.
Page 132: Chuck Change And Cleaning
Kongsberg XP User Manual 12.10.8. Chuck Change and Cleaning Clean the taper and the chuck regularly for proper operation and optimum life time; at least once a week, but more often if necessary. Follow the procedure strictly. Normally, the chuck has a long lifetime.
Page 133 Kongsberg XP User Manual Enter the Chuck Tool with a Dummy Bit into the chuck. 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.
Page 134 Kongsberg XP User Manual Push the Air Clean Button to help remove contamination. Taper Brush When cleaning the chuck, the taper brush must be free from grease or oil. If necessary, clean it with alcohol in advance. Grease or oil, even small quantities will reduce the clamping force significantly.
Page 135: Bit Slipping, Chuck Change
Chuck Change and Cleaning on page 132 WARNING: If a problem with bit slipping is not solved with a new chuck, then do not use the milling tool until it has been checked by Kongsberg personnell. New chucks are available from the webshop: https://kongsbergstore.com.
Page 136: Bit Length And Position
Kongsberg XP User Manual 12.10.10. Bit Length and Position Keep distance d small. For best performance and minimum wear, do not let the bit stick out more than necessary. Use bits with short cutting lengths for thin materials. For proper clamping, keep distance e 20 mm, 0.8 inch, as a minimum.
Page 137 Kongsberg XP User Manual 12.10.12. Table Top and Tool Height Adjustment The following rules apply when adjusting HPMU T = Cutting table C = Cutting Underlay Map table top function is carried out on top of the Cutting Underlay. U = Milling Underlay...
Page 138: Miscellaneous
Kongsberg XP User Manual 12.10.13. 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 139: Lubricool (3 Kw Milling Only)
Kongsberg XP User Manual Hint: • Make a file name that reflect the size used. • Prepare Layer Setup with low spindle speed, zero depth, and maximum feed. • Insert the Dummy Bit into the chuck. • Adjust the brush height until the brush barely touches the mat surface.
Page 140: How To Use
Kongsberg XP User Manual 12.10.14.2 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. Inspection Opening When the LubriCool unit is on, you can see light in the control relays inside the unit.
Page 141: Use Nozzle Unit Or Suction Ring
Kongsberg XP User Manual 12.10.14.3 Use Nozzle Unit or Suction Ring Nozzle Unit Suction Ring 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! •...
Page 142: Cleaning
Kongsberg XP User Manual 12.10.14.4 Cleaning Proper cleaning is crucial for correct operation. • Release locker A and remove the nozzle unit. • Use vacuum cleaner to clean the HPMU suction house. • Use vacuum cleaner to clean the nozzle unit.
Page 143: Startup
Kongsberg XP User Manual Connections and control Medium outlet Medium inlet Fill connection Temperature controller ON/OFF switch Electrical connection Potential equalizer Interface connection 12.11.2. Startup Ensure the following pre-requisites are in place for correct startup: NOTE: Never start the chiller without liquid.
Page 144 Kongsberg XP User Manual Three error codes are most common: • E05: Temperature of cooling liquid too low • E03: Water level too low or liquid flow too low • E04: Temperature of cooling liquid too high The display of an error code is alternating with the liquid temperature, and a warning triangle is flashing.
Page 145: Chiller 2020/2016 For Hpmu
Kongsberg XP User Manual 12.12. Chiller 2020/2016 for HPMU 12.12.1. 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 146: Startup
Kongsberg XP User Manual 12.12.2. 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 liquid level should be MAX. If not, fill with fresh water.
Page 147: Chiller No 1 (Blue Top) For Hpmu
Kongsberg XP User Manual hose. • Switch chiller unit OFF and ON again. 12.13. Chiller no 1 (blue top) for HPMU 12.13.1. Introduction 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.
Page 148: Chiller Heater, Operation
Kongsberg XP User Manual 12.13.2. Chiller Heater, Operation Notes: The Chiller Heater is optional. The Chiller Heater must be filled with water before connecting mains. The Chiller Heater is correctly configured when shipped from the factory. Normally, there is no need for modifications.
Page 149: Program Selection
Kongsberg XP User Manual Program selection Press and hold the Menu button for 3 sec. Use arrow keys to select program Press Menu button to confirm selection. Temperature setting Use arrow keys to select temperature Press Menu button to confirm selection.
Page 150: Chiller, Error Conditions
Kongsberg XP User Manual 12.13.3. 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) •...
Page 151 Kongsberg XP User Manual HF VibraCut (High Frequency VibraCut) 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: •...
Page 152 Kongsberg XP User Manual How to replace knife blade 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 153: Rm Knife
Kongsberg XP User Manual How to adjust VibraCut and HF VibraCut For this tool, complete the adjustments below. See Tool configuration and adjustment for how to adjust: Adjustment Description Lag Setting The Knife Lag depends upon the Blade Adapter. Nominal value is 0-3 mm.
Page 154: Hi-Force Knife
Kongsberg XP User Manual How to replace a knife blade Use a 3 mm allen key to fix/loosen the knife blade. Ensure the knife blade is correctly aligned. How to adjust RM Knife For this tool, complete the following adjustments. See Tool configuration and adjustment for details:...
Page 155 Kongsberg XP User Manual The Hi-Force (high force) Hi-Force Knife is a general purpose knife tool, suitable for cutting a wide range of flexible, paper based and rigid materials. As the name indicates; this tool is prepared for a higher tool pressure compared to other static knife tools.
Page 156: Psaligraphy Knife
Kongsberg XP User Manual Adjustment Description Tool Rotation Adjust Tool Angle tangential to Moving Direction. Center Offset Adjust Tool sideways until centered. Tool Offset Adjust offset relative to Laser Pointer. 12.17. Psaligraphy Knife NOTE: iPC version 2.0 or higher is required to run this tool.
Page 157: Presscut
Kongsberg XP User Manual How to adjust Psaligraphy Knife For this tool, complete the following adjustments, see Tool configuration and adjustment for details: Adjustment Description Lag Setting The Knife Lag depends upon the Blade Adapter. Nominal value is 0-3 mm.
Page 158 Kongsberg XP User Manual 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 159 Kongsberg XP User Manual Tool Pressure PressCut can run with a Constant Tool Pressure or a Speed Dependent Tool Pressure. Both parameters are specified in the Configure Tools or Opened Job->Layer structure. Constant Tool Pressure In the dialog, specify the Tool Pressure.
Page 160 Kongsberg XP User Manual 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: Press clamp C as indicated to lock the Knife Shaft.
Page 161: Rotacut Knife
Kongsberg XP User Manual 12.19. RotaCut knife RotaCut knife 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 tool, some restrictions apply: •...
Page 162 Kongsberg XP User Manual Use the spanner and the hexagonal screw driver to remove the knife blade fixing nut. Carefully remove the old knife blade and insert the new one. Ensure the knife blade is properly seated. Mount the nut and fix it properly.
Page 163 Verify by hand that the foot movement is smooth. How to adjust RotaCut tool RotaCut tool is adjusted in the same way as the other XP/C tools regarding rotation angle and offset. Tool height is manually adjusted: Tool height for RotaCut is manually adjusted using the tool height adjustment wizard available from the Tool configuration dialog.
Page 164: Braille Tool
Kongsberg XP User Manual WARNING: Be careful when working with different diameter blades (Ø25 and Ø28 mm). Tool height configuration must be redone in order to secure correct functionality and avoid any damage. Layer Setup for RotaCut. Correct setting of Lag- and Width - values are shown.
Page 165 Kongsberg XP User Manual One sphere should be pushed out from the tool Plunger The tool is equipped with a plunger that serves two purposes: To force the spheres into the internal funnel. Indicate the number of spheres remaining in the tool.
Page 166 Kongsberg XP User Manual Select Braille Tool and press Adjust Active Tool… Select Tool Offset Adjustment and press Next. Jog the tool head to the position of the tape so that the laser dot is placed in the middle of the piece of tape.
Page 167 Kongsberg XP User Manual 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 168: Corruspeed Knife Tool
Kongsberg XP User Manual On the other hand, if the spheres are not fully inserted into hard materials, like acrylic, you may increase this value to increase the force used by the Braille Tool. Drill Holes Drill Holes check box must be enabled for the Braille Tool to work properly.
Page 169 Kongsberg XP User Manual 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. crush. During processing, the corrugated material is partly crushed by the foot.
Page 170: How To Adjust Corruspeed
Kongsberg XP User Manual By this, you can find and save settings that are optimal for each type of material. How to insert knife blade When adjusting the knife tip exposure, do not adjust the knife tip too far into the foot.
Page 171 Kongsberg XP User Manual 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 172: Drill Tool
Kongsberg XP User Manual 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 173: Ball Point Pen
Kongsberg XP User Manual 12.24. Ball Point 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 174: Measuring Foot
Kongsberg XP User Manual 12.25. Measuring Foot The Measuring Foot (M) has 3 functions: Measure the thickness of the material on the table Map Table Top Surface. 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 175: Maintenance
Kongsberg XP User Manual 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 On a daily basis the user should: •...
Page 176: Monthly Maintenance
Kongsberg XP User Manual The automatic draining action of the Air Pressure Reduction Valve should be controlled: Switch off the Air Compressor and allow the air pressure to fall. Switch on the Air Compressor and check that any water in the glass bowl of the pressure reduction valve drains out automatically during the first few seconds of operation.
Page 177 Kongsberg XP User Manual X2 axis gear: Y axis gear: Racks The racks in X1, X2 and Y should be re-greased: 177 |...
Page 178 Kongsberg XP User Manual X1 (above) X2 (above) Y (above) Procedure 178 |...
Page 179 Kongsberg XP User Manual 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 180 Kongsberg XP User Manual 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. Check the conveyor Y position on the rollers front and rear.
Page 181: Maintenance, External Equipment
Kongsberg XP User Manual On lower rear roller, there are pneumatic mechanisms for auto-correction of the conveyor position. These will slightly move the roller in and out to corrigate the belt position. Observe the system in regular production. • If this movement is frequent, i.e. more often...
Page 182: Maintenance, Take Up Unit
Kongsberg XP User Manual 13.6. Maintenance, Take Up Unit 13.6.1. General There is no specific need for a maintenance interval for the TakeUp Unit . It is recommended to check the foam rubber on the Waste Handling kit daily for damage and if it is worn out.
Page 183: Fuse Replacement
Kongsberg XP User Manual 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 184 Kongsberg XP User Manual Procedure Remove base cover in front of MPU Remove one fuse and check with ohm-meter. If blown, replace with a new identical fuse. Repeat for each fuse. Replace base cover Insert main power cable into the wall socket and turn main power on.
Page 185: Fuse Location
Kongsberg XP User Manual Fuse Location 1 – 8/24A AC amplifier X1 2 – SCU unit Procedure Remove X1 cover. Remove cover from AC amplifier unit. Check fuses F2 – F5 with ohm - meter. If blown, replace with a new identical fuse.
Page 186 Kongsberg XP User Manual 14.3. X2 X2 Amplifier Location Fuse Location 186 |...
Page 187: 187
Kongsberg XP User Manual Procedure Remove X2 cover. Remove cover from AC amplifier unit. Check fuses F2 – F5 with ohm - meter. If blown, replace with a new identical fuse. Replace covers. Insert main power cable into the wall socket and turn main power ON.
Page 188: P1/P2 Fuses
Kongsberg XP User Manual Procedure Remove Y cover. Remove cover from AC amplifier unit. Check fuses F2 – F5 with ohm - meter. If blown, replace with a new identical fuse. Replace covers. Insert main power cable into the wall socket and turn main power ON.
Page 189 Kongsberg XP User Manual Fuse Location 1 – Y-motor with encoder. 2 – TCU. 3 – AC amplifier for Y. 4 – P1 – motor. 5 – P2 – motor Procedure Remove Y cover. On the TCU – unit, check fuses Fz1 and Fz2 with ohm - meter. If blown, replace with a new identical fuse.
Page 190: Tool Fuses
Kongsberg XP User Manual 14.6. Tool fuses Each tool has one or two fuses on the tool board. Tool board location Fuse location: Fhr - Tool rotation fuse. Fu/d - Tool up/down or tool reciprocation fuse. Procedure: Fuses are available on the tool board inside the actual tool.
Page 191: Chiller Hyfra (Blue Top) Fuse Replacement
Kongsberg XP User Manual Tool Head Function Fuse Fuse Fuse Type Size RotaCut Knife RPM T 2A 125V NANO (42441618) VariCut knife tool Tool rotation T 2A 125V NANO (42441618) VariCut knife tool Knife depth Fu/d T 0,5A 125V NANO (42441600)
Page 192: Heater For Chiller Fuse
Kongsberg XP User Manual 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) (42424150) Fuse when mains 230V: T 1A 250V (5x20 mm) (42468058) 14.8. ...
Page 193: Chiller Proficool (2016/2020) Fuse Replacement
Kongsberg XP User Manual 14.9. Chiller ProfiCool (2016/2020) Fuse replacement 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:...
Page 194 Kongsberg XP User Manual Circuit breaker for fan. When the Circuit Breaker is triggered The ON/OFF switch is in a middle position. For proper operation, ensure the ON/OFF switch A • Find and remove the root cause for the is in ON position.
Page 195: Takeup Unit, Fuse Replacement
Kongsberg XP User Manual 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. Fuse F1: T10 A, 250V, 5x20mm (42448985) The same fuse size is used regardless 115V/230V.
Page 196 Kongsberg XP User Manual Fuse 10F1: T10 A, 250 V, 5x20 mm (42448985) Fuse 10F3: T3.15 A, 250 V, 5x20 mm (42476168) Fuse 15F1: T100 mA, 250 V, 5x20 mm (42476184) Fuse 15F2: T5 A, 250 V, 5x20 mm (42448951)
Page 197: Roll Feeder
Kongsberg XP User Manual 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 198: Collector Basket
Kongsberg XP User Manual 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 199: Takeup Unit
Kongsberg XP User Manual 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 200: Machine Description
Kongsberg XP User Manual The warranty on your equipment become null and void if: • 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.
Page 201: Safety
Kongsberg XP User Manual 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. When the dancer roller lowers in the TakeUp Unit, the machine will start winding the material till the dancer roller rises to his neutral zone.
Page 202 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 Kongsberg PCS is not responsible for any resulting damage to machine or individuals.
Page 203: Features And Components
Kongsberg XP User Manual Intended use does include: • Following all instructions in this manual. • Carrying out inspection and maintenance operations. Safety Features • Before start-up of the machine, make sure that all safety features are properly installed and operational.
Page 204: General Operation
Kongsberg XP User Manual 17.5. General operation Control positions The TakeUp Unit is normally operated from the right side of the machine. Controls At the left side of the frame are the operating switches. These switches allow the operator to control the power (on or off), the turning direction, the winding speed and the possibility to jog the machine.
Page 205: Applying Winding Material
Kongsberg XP User Manual 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 206: Start The Takeup Unit
Kongsberg XP User Manual 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.
Page 207: Using The Autogrip Shaft
Kongsberg XP User Manual 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 208 Kongsberg XP User Manual 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 209 Kongsberg XP User Manual 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 210: Vacuum Cleaner
Kongsberg XP User Manual VACUUM CLEANER 18.1. Vacuum Cleaner, High-capacity (Zefiro 75) 18.1.1. How to use 18.1.1.1 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 211: Remove Material Container
Kongsberg XP User Manual 18.1.1.2 Remove Material Container Note: You can use the container with or without Plastic Bag. 211 |...
Page 212: Use Plastic Bag In Material Container
Kongsberg XP User Manual 18.1.1.3 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 Fold/fix the Plastic Bag around the container...
Page 213: Vacuum Cleaner, High-Capacity (Depureco)
Kongsberg XP User Manual 18.2. Vacuum Cleaner, High-capacity (Depureco) 18.2.1. How to use 18.2.1.1 Introduction 1 – Filter Chamber 2 – Filter Shaking Lever 3 – Removable Material Container Note: Carefully observe the Vacuum Cleaner filling level. If the Vacuum Cleaner container is filled up completely, the dust removal function will stop with a high risk for Spindle Motor damage.
Page 214: Remove Material Container
Kongsberg XP User Manual 18.2.1.3 Remove Material Container Note: You can use the container with or without Plastic Bag. 18.2.1.4 Use Plastic Bag in Material Container Shake the filter well before emptying the container. Fix the Plastic Bag to the steel bar.
Page 215: Compact Vacuum Cleaner
Kongsberg XP User Manual Plastic Bag with bar ready for container. Fold/fix the Plastic Bag around the container. Container with Plastic Bag ready for operation. Detailed information about how to operate the Vacuum Cleaner is available in the Operators and maintenance manual.
Page 216 Kongsberg XP User Manual Suction tube inlet Container fixture Filter unit locking mechanism Motor Filter unit How to empty container Ensure vacuum cleaner motor is off. Remove the suction tube (1). Release the container (3). Remove the filter unit (5).
Page 217: Install Software
Kongsberg XP User Manual INSTALL SOFTWARE For information about software installation, see the Installation Manual for the actual machine. 217 |...
Page 218: Frequently Asked Questions
During start up: X1/X2/Y servo error This is probably caused by a defect in an amplifier board. Please contact Kongsberg 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 219 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 Kongsberg 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 220 Kongsberg XP User Manual Check the connection at the emergency button 220 |...

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