Esko Kongsberg C series Specification sheet

Kongsberg C-series
How to Get Started
09 - 2020 | Kongsberg C-series

Kongsberg C-series
Contents
1. Preface........................................................................................................................................................... 4
2. Change record............................................................................................................................................... 6
3. Introduction....................................................................................................................................................7
3.1. Welcome................................................................................................................................................7
3.2. System Label........................................................................................................................................ 7
3.3. EC Declaration of Conformity............................................................................................................... 8
3.4. RoHS Compliance Declaration.............................................................................................................. 9
4. General Information..................................................................................................................................... 10
4.1. Where to find information................................................................................................................... 10
4.2. Site preparation...................................................................................................................................11
4.3. User manuals....................................................................................................................................... 11
4.3.1. User manual for cutting table.....................................................................................................11
4.3.2. User manual for iPC...................................................................................................................11
4.3.3. Get the best out of iPC............................................................................................................. 12
4.4. Installation.......................................................................................................................................... 12
4.4.1. What is received........................................................................................................................12
4.4.2. Unpack Equipment................................................................................................................... 12
4.5. Table Operation...................................................................................................................................12
4.5.1. Power On Sequence...................................................................................................................12
4.5.2. Reset Safety System................................................................................................................. 13
4.5.3. Power Off Sequence................................................................................................................. 14
4.5.4. Continue after Safety Break......................................................................................................14
4.6. Software updates................................................................................................................................ 15
4.7. Maintenance........................................................................................................................................ 15
5. Safety Regulations....................................................................................................................................... 17
5.1. Introduction..........................................................................................................................................17
5.2. Responsibilities................................................................................................................................... 17
5.2.1. The manufacturer...................................................................................................................... 17
5.2.2. The owner................................................................................................................................. 17
5.2.3. The operators............................................................................................................................18
5.3. Requirements to be met by operators.................................................................................................18
5.4. Definition of use..................................................................................................................................19
5.5. Warning sign explanation.................................................................................................................... 19
5.6. Attention areas...................................................................................................................................22
5.6.1. Mains power disconnection.......................................................................................................22
5.6.2. High voltage, laser radiation and moving parts.........................................................................22
5.6.3. Loose clothing..........................................................................................................................23
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Contents
5.6.4. Noise level................................................................................................................................ 23
5.6.5. Ejection of parts when milling..................................................................................................23
5.6.6. Milling stop time....................................................................................................................... 23
5.6.7. i-Camera strobing light.............................................................................................................24
5.7. Safety devices.....................................................................................................................................25
5.7.1. Overview....................................................................................................................................25
5.7.2. Emergency stop button............................................................................................................ 25
5.7.3. Yellow/black tape......................................................................................................................26
5.7.4. Warning lamps on Y carriage.................................................................................................... 27
5.7.5. DynaGuard safety system.......................................................................................................... 27
5.7.6. Milling warning lamp................................................................................................................. 28
5.8. Protective equipment......................................................................................................................... 29
5.9. Procedures in case of Malfunctions....................................................................................................29
5.10. Check before operation.....................................................................................................................29
5.11. Residual risks.....................................................................................................................................30
6. Additional safety instructions.................................................................................................................... 33
6.1. Milling tool........................................................................................................................................... 33
6.1.1. Read the user manual................................................................................................................ 33
6.1.2. Qualified operators only............................................................................................................ 33
6.1.3. Safety issues............................................................................................................................. 33
6.2. Roll feeder.......................................................................................................................................... 35
6.2.1. Read the user manual............................................................................................................... 35
6.2.2. Roll feeder safety warnings...................................................................................................... 36
6.3. TakeUp unit.........................................................................................................................................36
6.3.1. Read the user manual............................................................................................................... 36
6.3.2. Safety issues............................................................................................................................ 36
6.4. Motorized roll feeder (MRF)................................................................................................................. 37
6.4.1. Read the user manual............................................................................................................... 37
6.4.2. Safety issues............................................................................................................................ 38
6.5. i-BF board feeder and i-MS material stacker...................................................................................... 39
6.5.1. Read the user manual............................................................................................................... 39
6.5.2. Safety issues............................................................................................................................ 40
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1Kongsberg C-series
1. Preface
How to get started
with
Kongsberg C-series
Serial no:______________
PLEASE READ THIS FIRST
©Copyright 2020, Esko-Graphics Kongsberg AS, Norway
All Rights Reserved.
This copyright does not indicate that this work has been published.
This material, information and instructions for use contained herein are the property of Esko-Graphics Kongsberg AS. There
are no warranties granted or extended by this document. Furthermore, Esko-Graphics Kongsberg AS does not warrant,
guarantee or make any representations regarding the use, or the results of the use of the system or the information contained
herein. 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. The information contained herein is
subject to change without notice. Revisions may be issued from time to time to advise of such changes and/or additions.
No part of this system may be reproduced, stored in a data base or retrieval system, or
published, in any form or in any way, electronically, mechanically, by print, photoprint, microfilm
or any other means without prior written permission from Esko-Graphics Kongsberg AS.
This document supersedes all previous dated versions.
Correspondence regarding this publication should be forwarded to:
Global support
Esko-Graphics Kongsberg AS
Note: We remind you that only the Esko 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.
Disclaimer: Do not operate this equipment in an EU member State if the Instructions are not written in
that State's language. Contact Esko if a translation is needed.
Document: D3631
Part no: 32462632 (US version)
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Kongsberg C-series
Esko-Graphics Kongsberg AS
www.esko.com
P.O.Box 1016, NO-3601 Kongsberg, NORWAY
Tel.: [phone]
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2. Change record
Date
dd-mm-yyyy
By Description
20.06.2014 JHBE First edition of this document
02.05.2016 JHBE Certificates updated
13.11.2018 DHO New certificates and other minor updates.
03.06.2020 DHO Safety sections updated. Declarations and statements
updated.
23.09.2020 DHO Section FCC conformity statement removed.
Safety Regulations updated.
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Kongsberg C-series
3. Introduction
3.1. Welcome
Welcome to a long-lasting co-operation with Esko.
This How to get started manual is a brief introduction to the system you are about to receive.
It should stay available to operators all time.
3.2. System Label
A System Label is available from:
• Bottom plate of RWS or Front panel, depending upon machine model.
• MPU Cabinet.
System Label, sample:
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3.3. EC Declaration of Conformity
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Kongsberg C-series
3.4. RoHS Compliance Declaration
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4. General Information
4.1. Where to find information
The following documentation is available for the equipment:
Title Target personnel Media Language Purpose
How to get started
manual
Customer PDF Local and US Shortform
introduction
How to get started
manual
Customer Printed Local
(EU countries)
Shortform
introduction
Site preparation
manual
Customer PDF Local and US How to prepare for
installation.
User manual for
cutting table, incl.
maintenance
Customer PDF Local and US User Manual
User manual for
iPC
Customer PDF Local and US User Manual iPC
Get the best out of
iPC
Customer PDF US User manual iPC
Technical
Reference
Tech. support
personnel
PDF US Technical
information for
special purpose
Test manual Service PDF US How to run Hwtest
test programs
Technical manual Service PDF US Technical
information aimed
for service needs
Installation manual Service PDF US Technical
information aimed
for service needs
Maintenance
manual
Service PDF US Technical
information aimed
for service needs
Training
documentation
Customer Printed, PDF US, DE, FR, ES Customer training
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Kongsberg C-series
4.2. Site preparation
In the Site preparation manual, all information needed for planning and preparing the installation of
the Kongsberg system is available.
All preparations specified in that handbook should be completed before the service engineer arrives
on-site to install the system. 
All technical data and requirements about the equipment are available from the site preparation
manual.
4.3. User manuals
User manuals - availability
From the help menu in iPC, user manuals for cutting table and iPC are available online. These are
updated regularly.
Factory installed PCs have All documentation loaded to C:\Users\Public\Documents\Esko
documentation. This folder can also be accessed from the help menu. The content is sorted on
available languages. Please note that some documentation is available in English only.
Note:
For XE machines, which are using XE-Guide, not iPC, please disregard information about iPC.
4.3.1. User manual for cutting table
The User manual for cutting table contains all information needed about:
• Operator safety.
• How to operate the system.
• How to adjust the system properly.
• System description.
• Daily maintenance.
4.3.2. User manual for iPC
The User manual for iPC contains
• iPC system description
• iPC configurations and optimizations
• Preparing and running simple jobs
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• Advanced job alternatives
4.3.3. Get the best out of iPC
Get the best out of iPC is available in US version online, and contains advice on how to prepare
different types of jobs from design, prepress and to finishing.
4.4. Installation
Esko Authorized Personnel only are allowed to install the equipment.
4.4.1. What is received
The delivery is specified in a Packing List following the shipment.
4.4.2. Unpack Equipment
Esko Authorized Personnel only are allowed to unpack the equipment.
4.5. Table Operation
For detailed information on how to operate the system, be familiar with the User manual and complete
the following sequences:
• Get started.
• Basic operation.
• Table setup.
• Tool heads and tools.
4.5.1. Power On Sequence
Ensure the table is free from obstructions and ready for operation.
Follow these steps to power up the system and get ready to work:
1 Front End PC
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Kongsberg C-series
Switch on the PC and the monitor.
2 Table Power
Switch the table on using the Main Power Switch.
Note: After power off, wait minimum 5 sec. before the system is switched on again.
3 iPC
Use the mouse, double-click the icon for iPC.
Check that no error message indicates faulty conditions.
4 Safety System
Reset the Safety System by pressing the Pause pushbutton.
5 Servo Power
Press the Servo On pushbutton.
The Warning Lamp on top of the Y carriage should be constantly lit. Any malfuction
of the lamp must be corrected as soon as possible since this is a safety feature.
6 Table Zero Sequence
Press Start to complete the Table Zero Sequence.
The machine will move to the Selected Reference Point.
7 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. Any malfunction of the lamp must be corrected as soon as possible since
the lamp is a safety feature.
8The table is now ready for operation.
4.5.2. Reset Safety System
After June-September 2018
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Safety Reset is now combined with Servo On.
There is no separate Safety Reset button.
Before June-September 2018
Press Pause to Reset Safety System.
4.5.3. Power Off Sequence
Follow these steps to power down the system:
1 Servo Power
Press the Servo On push button to switch Servo Off.
2 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.
3 Front End PC
To switch off the PC, use the Operating System shutdown procedure..
4.5.4. 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:
After June-September 2018
1Ensure the table is free from obstructions and ready for operation.
2Press the Servo On push button to:
• Reset Safety System
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Kongsberg C-series
• Switch Servo Power on
3 Servo Power
Observe that Servo Power is switched on,
The Warning Lamp on top of the Y carriage is on.
4Press Start to continue.
Before June-September 2018
1Ensure the table is free from obstructions and ready for operation.
2 Safety System
Reset the Safety System by pressing the Pause pushbutton.
3 Servo Power
Observe that Servo Power is switched on,
The Warning Lamp on top of the Y carriage must be on without flashing.
4Press Start to continue.
4.6. Software updates
Follow the installation procedure in the Installation manual.
4.7. Maintenance
Maintenance done by the customer is limited to simple, preventive maintenance and cleaning.
This is described in the User manual as well as in the Maintenance manual.
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Any other maintenance, repair, replacement of parts etc. must be done by Esko authorized personnel
only.
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Kongsberg C-series
5. Safety Regulations
5.1. Introduction
The Kongsberg C-series system is designed to conform to applicable 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.
In particular, operating the table can involve hazards if:
• The operator does not follow the operating instructions.
• The table is used for non-intended purposes.
Special attention should be paid upon the following:
• Be careful when handling tools with knife blades. Knives are extremely sharp.
• Be careful when operating the milling tool. The milling spindle needs a few seconds to stop, and any
contact with a rotating milling bit is very dangerous.
• Use appropriate techniques and tools when handling heavy materials.
• The machine has fast moving parts like the traverse and tool head. Stay away from the danger zone
during operation.
• The system is equipped with a class II laser pointer. Do not stare directly into it. That can damage
your eyes.
In addition to the safety regulation described below, there are safety warnings in the respective topics.
5.2. Responsibilities
5.2.1. The manufacturer
The manufacturer is responsible for delivering the system according to safety regulation standards.
5.2.2. The owner
The owner is responsible for:
• Ensuring that the system is used for its intended use only
• Ensuring that only authorized and trained personnel operate the system
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• Preventive maintenance as described in the maintenance section of the user manual
• That the local Regulations regarding installation and operation are fulfilled
• Ensure that safe work procedures and awareness of potential hazards are periodically reviewed and
enforced
5.2.3. The operators
The operators are responsible for:
• Operating the system only when it is in a flawless state
• Operating the system according to operating instructions
• Ensuring that no unauthorized personnel come close to the system.
5.3. Requirements to be met by operators
Personnel operating the system must:
• Be adequately trained.
• Have read and understood the instructions described in safety regulation as well as any other safety
warnings.
Training will be given to operator(s) nominated by the customer by the Esko service engineer as part
of the system installation.
The training covers:
• Safety regulations
• Start-up and shut-down procedures
• Online help / user manuals
• Set-up procedures
• Adjustment procedures
• Workflow
• Maintenance
For additional training courses, contact Esko global support.
Un-trained personnel shall under no circumstances be allowed to operate the system!
Note: We remind you that only the Esko staff, or persons having received appropriate training, are
allowed to handle, manipulate or do repairs on the system.
In particular, milling operations shall only be performed by properly trained operators due to the
dangerous nature of the milling tool.
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5.4. Definition of use
The system is designed for use within applications, materials, tools and workflow as described in the
user manual for iPC. In the user manual for cutting table, intended use is described in the following
sections:
•Basic Operations
•Prepare for a Job
•How to Procedures, Advanced
Any other use is considered as non-intended use. Examples of non-intended use:
• Operation by operators not meeting the requirements as described above.
• Unauthorized modifications (bridging safety devices, removing covers etc.)
• Deliberately avoiding the DynaGuard safety system by reaching under the lower beam to avoid
detection.
• Utilizing accessories other than those specified by Esko.
• Operating or maintaining the machine or any of its accessories under the influence of drugs, alcohol
or medication that could impair your judgment and vigilance.
Non-intended use may cause:
• Health hazards and injuries.
• Damage to the system.
• Incorrect functionality.
• Damage to work materials.
Note: Esko is not liable for any damage resulting from such non-intended use.

5.5. Warning sign explanation
High voltage warnings
• Main Power Unit (MPU) and vacuum pump
Do not open cover on either MPU or vacuum pump before mains is
disconnected from cutting table and vacuum pump.
Note: Different instruction for Cxx and Xxx.
• IBAG inverter
Do not open cover on IBAG inverter before mains is disconnected from cutting
table.
Note: Different instruction for Cxx and Xxx.
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•Chiller
Do not open cover on chiller before mains is disconnected from cutting table.
Note: Different instruction for Cxx and Xxx.
• Vacuum cleaner
Do not open cover on vacuum cleaner before mains is disconnected from
cutting table.
Note: Different instruction for Cxx and Xxx.
Note: Equipment with high voltage may be opened by authorized personnel only.
Caution, laser
LASER RADIATION
DO NOT STARE INTO BEAM
DIODE LASER
MAX OUTPUT 1 mW
WAVELENGTH 650-660 nm
EN 60825-1: 1991+A11:1996
CLASS II LASER PRODUCT
AVOID EXPOSURE
Laser radiation emitted from this aperture
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 Squeeze
Potential areas with a risk of being squeezed are marked with the Hand Squeeze
sign.
These areas are:
• Between X-axis end stopper and traverse wagon.
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