Esko Kongsberg C series User manual

Kongsberg C-series
User Manual
05 - 2018 | C-series

Kongsberg C-series
Contents
1. Preface.........................................................................................................................................................9
2. Change Record......................................................................................................................................... 10
3. Welcome....................................................................................................................................................11
4. Using this manual................................................................................................................................... 12
4.1. Main Sections.................................................................................................................................. 12
4.2. Name Styles and Symbols..............................................................................................................13
4.3. Pictures and Illustrations................................................................................................................13
4.4. Local Languages.............................................................................................................................. 14
5. Safety Regulations.................................................................................................................................. 15
5.1. Introduction..................................................................................................................................... 15
5.2. Responsibilities................................................................................................................................15
5.2.1. The Manufacturer................................................................................................................. 15
5.2.2. The Customer........................................................................................................................15
5.2.3. The Operators....................................................................................................................... 15
5.3. Requirements to be met by Operators.........................................................................................16
5.4. Definition of Use............................................................................................................................. 16
5.5. Warning Sign Explanation.............................................................................................................. 17
5.6. Attention Areas................................................................................................................................19
5.6.1. Moving Parts, Laser Radiation and High Voltage............................................................... 19
5.6.2. Loose Clothing...................................................................................................................... 19
5.6.3. Noise Level............................................................................................................................ 19
5.6.4. Ejection of Parts....................................................................................................................20
5.6.5. i-Camera strobing light.........................................................................................................20
5.7. Safety Devices..................................................................................................................................21
5.7.1. Overview................................................................................................................................ 21
5.7.2. Emergency Stop Button....................................................................................................... 21
5.7.3. Yellow / Black tape................................................................................................................22
5.7.4. Warning Lamp on top of Y carriage....................................................................................23
5.7.5. DynaGuard Safety System................................................................................................... 23
5.8. Protective Equipment..................................................................................................................... 24
5.9. Procedures in case of Malfunctions.............................................................................................. 25
5.10. Residual Risk..................................................................................................................................25
6. System Description................................................................................................................................. 27
6.1. Naming Conventions...................................................................................................................... 27
6.2. Front End PC....................................................................................................................................28
6.3. Operator Station............................................................................................................................. 29
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Contents
6.4. Main Power Switch......................................................................................................................... 30
6.5. Operator Panel................................................................................................................................ 30
6.6. Traverse Panel................................................................................................................................. 34
6.7. Foot Pedal........................................................................................................................................34
6.8. High Pressure Air System...............................................................................................................34
6.9. Application Programs Available..................................................................................................... 35
7. Basic Operations..................................................................................................................................... 36
7.1. Introduction..................................................................................................................................... 36
7.2. Power On Sequence....................................................................................................................... 36
7.3. Reset Safety System........................................................................................................................38
7.4. Power Off Sequence....................................................................................................................... 38
7.5. Continue after Safety Break...........................................................................................................39
8. Prepare for a Job..................................................................................................................................... 41
8.1. Introduction..................................................................................................................................... 41
8.2. Create Job........................................................................................................................................ 41
8.3. Layer Setup......................................................................................................................................41
8.4. Production Setup............................................................................................................................ 42
8.5. Speed Setting...................................................................................................................................42
8.6. Flute/Grain Direction.......................................................................................................................42
8.7. Vacuum Zone Selection.................................................................................................................. 42
8.8. Job Execution................................................................................................................................... 43
8.9. Corrugated Production................................................................................................................... 44
8.10. Milling Production......................................................................................................................... 44
8.11. Make a Pen Plot............................................................................................................................ 44
9. How To Procedures, Advanced............................................................................................................. 45
9.1. Cutting Thick Materials...................................................................................................................45
9.2. Hard Board Production.................................................................................................................. 45
9.3. Multi Pass Creasing or Milling....................................................................................................... 46
9.4. Jobs including Reverse Operations................................................................................................47
9.5. Work with different Reference Point Settings.............................................................................. 48
9.6. MultiZone Production..................................................................................................................... 48
9.6.1. MultiZone, Workflow.............................................................................................................50
10. System Setup......................................................................................................................................... 52
10.1. Introduction................................................................................................................................... 52
10.2. Adjust X1 to X2 Angle................................................................................................................... 53
10.3. Register Table Size........................................................................................................................ 54
10.4. Adjust Measuring Station Position.............................................................................................. 54
10.5. Set Ruler Position..........................................................................................................................54
10.6. Set Main Reference Point.............................................................................................................55
10.7. Map Table Top Surface.................................................................................................................55
10.8. Calibrate Foot on Measuring Station.......................................................................................... 56
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Kongsberg C-series
10.9. Reference Points and Coordinate System.................................................................................. 56
10.10. Table Speed................................................................................................................................. 59
10.11. Table Acceleration....................................................................................................................... 60
10.12. Jog Settings.................................................................................................................................. 60
10.13. Set Table Top Reference.............................................................................................................61
10.14. Vacuum Setup............................................................................................................................. 61
10.14.1. Vacuum Zone Configuration............................................................................................61
10.15. Router Setup............................................................................................................................... 63
10.16. Conveyor Belt Control................................................................................................................ 64
10.16.1. Split Sheet Feed................................................................................................................ 64
10.16.2. Sheet Feed Correction......................................................................................................64
10.17. Board Size....................................................................................................................................65
11. Tool Configuration and Adjustment..................................................................................................66
11.1. Tool Configuration.........................................................................................................................66
11.2. Tool Names....................................................................................................................................67
11.3. Adjust Active Tool..........................................................................................................................68
11.4. Lag Settings (for Rotating Tools)..................................................................................................68
11.5. Tool Height Calibration.................................................................................................................70
11.6. Rotation Adjustment (for Rotating tools)....................................................................................70
11.7. Center Offset Adjustment............................................................................................................ 71
11.8. Tool Offset..................................................................................................................................... 72
11.9. Maintain Tool List..........................................................................................................................73
12. Tooling System....................................................................................................................................... 75
12.1. Introduction................................................................................................................................... 75
12.2. Tool Handling and Care................................................................................................................75
12.3. How to Replace a Tool..................................................................................................................76
12.4. Two or more tools of the same type.......................................................................................... 76
12.5. Measuring Station......................................................................................................................... 77
12.6. HDU - Heavy-Duty Unit................................................................................................................ 78
12.6.1. Crease Wheel ø150 mm.....................................................................................................79
12.6.2. V-notch Knife Tool.............................................................................................................. 81
12.6.3. HD Knife Tool...................................................................................................................... 87
12.6.4. Crease Adapter................................................................................................................... 89
12.6.5. Perforation Wheel ø60 mm............................................................................................... 89
12.6.6. Bevel Knife 45..................................................................................................................... 91
12.7. Foam Knife.....................................................................................................................................93
12.8. HPMU - High Power Milling Unit................................................................................................. 95
12.8.1. Introduction.........................................................................................................................95
12.8.2. Tool Head description........................................................................................................ 97
12.8.3. HPMU with no-gallows solution........................................................................................ 99
12.8.4. Safety Issues..................................................................................................................... 100
12.8.5. Precautions........................................................................................................................102
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Contents
12.8.6. Routing Advice.................................................................................................................. 105
12.8.7. Cleaner Device.................................................................................................................. 108
12.8.8. Bits and Bit Change..........................................................................................................108
12.8.9. Chuck Change and Cleaning............................................................................................110
12.8.10. Bit Slipping, Chuck Change............................................................................................114
12.8.11. Bit Length and Position................................................................................................. 114
12.8.12. Tool Adjustment..............................................................................................................115
12.8.13. Table Top and Tool Height Adjustment........................................................................ 115
12.8.14. Miscellaneous..................................................................................................................116
12.8.15. LubriCool......................................................................................................................... 117
12.9. Chiller no 1 for HPMU................................................................................................................121
12.9.1. Introduction.......................................................................................................................121
12.9.2. Chiller Heater, Operation.................................................................................................122
12.9.3. Chiller, Error Conditions...................................................................................................123
12.10. Chiller2016 for HPMU...............................................................................................................124
12.10.1. Introduction.....................................................................................................................124
12.10.2. Startup............................................................................................................................. 125
12.10.3. Error Conditions............................................................................................................. 125
12.11. VibraCut..................................................................................................................................... 126
12.12. Rigid Material Knife (RM Knife Tool)........................................................................................129
12.13. HiForce Knife............................................................................................................................. 130
12.14. Psaligraphy Knife.......................................................................................................................132
12.15. PressCut..................................................................................................................................... 134
12.16. RotaCut...................................................................................................................................... 137
12.17. Braille Tool................................................................................................................................. 140
12.18. CorruSpeed Knife......................................................................................................................145
12.18.1. Tool adjustment..............................................................................................................147
12.19. Braille Tool................................................................................................................................. 147
12.20. Drill / Pen Tool...........................................................................................................................152
12.21. Drill Tool.....................................................................................................................................154
12.22. Ballpoint Pen............................................................................................................................. 155
12.23. Measuring Foot......................................................................................................................... 156
12.24. Laser Pointer............................................................................................................................. 156
13. Maintenance........................................................................................................................................ 157
13.1. General.........................................................................................................................................157
13.2. Daily Maintenance...................................................................................................................... 157
13.3. Weekly Maintenance...................................................................................................................157
13.4. Monthly Maintenance.................................................................................................................158
13.5. Maintenance, External Equipment............................................................................................ 159
14. Fuse Replacement...............................................................................................................................160
14.1. Mains fuses inside MPU.............................................................................................................160
14.2. MPU fuses....................................................................................................................................161
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14.3. X1 amplifier................................................................................................................................. 162
14.4. X2 amplifier................................................................................................................................. 163
14.5. Y amplifier....................................................................................................................................164
14.6. P1/P2 fuses..................................................................................................................................166
14.7. Tool Rotation/Reciprocating Knife............................................................................................. 167
14.8. Chiller1 fuse.................................................................................................................................168
14.9. Heater for Chiller Fuse............................................................................................................... 169
14.10. Chiller2016 Fuse replacement................................................................................................. 169
14.11. TakeUp Unit, Fuse replacement...............................................................................................170
15. Roll Feeder............................................................................................................................................172
15.1. Roll Feeder Safety Warnings...................................................................................................... 172
15.2. Roll Feeder Mount...................................................................................................................... 173
15.3. Roll Feeder Use........................................................................................................................... 173
16. Collector Basket.................................................................................................................................. 176
17. TakeUp Unit..........................................................................................................................................177
17.1. Introduction................................................................................................................................. 177
17.2. Machine Description...................................................................................................................178
17.3. Safety............................................................................................................................................179
17.4. Features and components......................................................................................................... 182
17.5. General operation.......................................................................................................................182
17.6. Applying Winding Material......................................................................................................... 184
17.7. Start the TakeUp Unit................................................................................................................. 185
17.8. Using the Autogrip Shaft............................................................................................................185
18. i-BF Board Feeder................................................................................................................................188
18.1. Introduction................................................................................................................................. 188
18.2. Health and Safety....................................................................................................................... 189
18.3. i-BF Specific Warnings................................................................................................................ 190
18.4. Rules for Safe Operation............................................................................................................192
18.5. Overview of Safety System........................................................................................................ 194
18.6. i-BF Overview...............................................................................................................................196
18.7. Power On/Off Controls...............................................................................................................198
18.8. Operator Controls....................................................................................................................... 199
18.9. Feeder Sequence of Operation................................................................................................. 202
18.10. Touch Screen Display for Feeder Operation.......................................................................... 203
18.11. Starting Up the i-BF for Daily Operation................................................................................ 206
18.12. Machine Faults, Errors and Remedies.................................................................................... 207
18.13. Suction Cups for Board Feeder............................................................................................... 211
18.14. Emergency Stop Solution......................................................................................................... 212
19. i-BF Board Stacker...............................................................................................................................215
19.1. Introduction................................................................................................................................. 215
19.2. Health and Safety....................................................................................................................... 215
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Contents
19.2.1. About this section.............................................................................................................215
19.2.2. Safety warnings in this manual.......................................................................................216
19.2.3. Safety Symbols on Feeder/Stacker System.................................................................... 216
19.2.4. Feeder and Stacker Specific Warnings............................................................................218
19.2.5. Rules for Safe Operation................................................................................................. 219
19.3. Overview of Safety System........................................................................................................ 221
19.3.1. Emergency Stop Safety Circuit........................................................................................ 222
19.3.2. Emergency Stop Push buttons........................................................................................ 222
19.3.3. Safety Bumpers.................................................................................................................222
19.4. Machine Overview.......................................................................................................................224
19.4.1. Feeder Machine Components......................................................................................... 224
19.4.2. Stacker Machine Components.........................................................................................225
19.5. Power On/Off Controls...............................................................................................................227
19.6. Operator Controls....................................................................................................................... 228
19.7. Feeder Sequence of Operation................................................................................................. 230
19.8. Touch Screen Display for Feeder Operation............................................................................ 232
19.8.1. Feeder Main Screen..........................................................................................................233
19.8.2. Jog Functions Screen........................................................................................................ 235
19.8.3. Feeder Setting Screen 1...................................................................................................235
19.8.4. Feeder Setting Screen 2...................................................................................................236
19.8.5. Shaker Option................................................................................................................... 237
19.8.6. Feeder Machine Speed.................................................................................................... 238
19.8.7. Place to Cutter Method....................................................................................................238
19.8.8. System Information..........................................................................................................239
19.8.9. Access System Protected Settings...................................................................................240
19.9. Stacker Sequence of Operation.................................................................................................246
19.10. Touch Screen Display for Stacker Operation..........................................................................247
19.10.1. Stacker Main Screen.......................................................................................................247
19.10.2. Jog Functions Screen...................................................................................................... 249
19.11. Starting Up the Feeder and Stacker for Daily Operation.......................................................249
19.12. Machine Faults, Errors and Remedies.................................................................................... 251
19.13. Suction Cups for Board Feeder............................................................................................... 255
19.14. Emergency Stop Solution......................................................................................................... 256
20. Vacuum Cleaner.................................................................................................................................. 258
20.1. Vacuum Cleaner, Zefiro.............................................................................................................. 258
20.1.1. How to use........................................................................................................................ 258
20.2. Vacuum Cleaner, High-capacity, TB ESKO.................................................................................260
20.2.1. How to use........................................................................................................................ 260
20.3. Compact Vacuum Cleaner..........................................................................................................263
20.3.1. How to use........................................................................................................................ 263
21. Install Software................................................................................................................................... 265
22. Frequently Asked Questions.............................................................................................................266
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Kongsberg C-series
22.1. Machine........................................................................................................................................266
22.2. Tools............................................................................................................................................. 266
22.3. iPC.................................................................................................................................................267
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1
Kongsberg C-series
1. Preface
User Manual
for
Kongsberg C-series
running i-cut Production Console 2.1
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.
©Copyright 2018, 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
Document no: D3621
Part no: 32597544
Esko-Graphics Kongsberg AS
www.esko.com
P.O.Box 1016, N-3601 Kongsberg, Norway
Tel: [phone] Fax: [phone]
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2Kongsberg C-series
2. Change Record
Date
dd-mm-yy
By Description
03-02-2017 jhbe TakeUp Unit, information added
28-02-2017 jhbe i-BF Board Feeder, information updated
18-04-2017 jhbe Measuring station operation, information
added.
20-04-2017 jhbe Braille tool description added
20-04-2017 jhbe Bevel 45 tool adapter description added
04-05-2017 jhbe Never run Milling Unit when TakeUp Unit is
mounted
20-05-2017 jhbe Safety Reset is moved from Pause button to
Servo On button.
03-07-2017 jhbe Incremental Jog function modified
03-07-2017 jhbe Tool Insert Position, limitation information
added.
07-08-2017 jhbe The importance of Braille tool height
adjustment has been emphasized.
28-08-2017 jhbe The use of LubriCool Nozzle Unit and Suction
Ring, description added.
30-08-2017 jhbe Braille tool info added.
02-11-2017 jhbe Modifications due to updated CIB and sw:
• Basic Operations chapter modified.
• Operator Panel description modified.
06-11-2017 jhbe Droplets from cooling water connections,
description added
17-11-2017 jhbe Board Stacker, information added.
01-12-2017 jhbe Motorized Roll Feeder, information added
17.03.2018 DHO Motorized Roll Feeder, information removed.
Work area information added.
11.05.2018 DHO Operator panel upgrade June-September 2018
included + misc.
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Kongsberg C-series
3. Welcome
Welcome to the User Manual for Kongsberg C series running iPC.
This manual will provide a complete and detailed description of all Cutting Table functions.
There is a separate user manual for i-cut Production Console (iPC). Thus, actual GUI functions
will be referenced in this manual, but the complete and comprehensive description is available
in the User Manual for i-cut Production Console.
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 2.0.
Note: Some of the functions and equipments described in this manual are optional.
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4Kongsberg C-series
4. Using this manual
4.1. Main Sections
The manual is divided into the following Main Sections:
Safety Regulations
• All safety related issues are discussed.
System Description
• This chapter provides basic knowledge about the machine.
Basic Operations
• This chapter provides basic knowledge about how to operate the machine.
Prepare for a Job
• A typical workflow is described, with detailed information about each step.
How to Procedures, Advanced
Optional functions for the advanced user:
•Cutting Thick Materials - advices.
•Hard Board Production - advices.
•Multi Pass Creasing or Milling - how to.
•Jobs including Reverse Operations - how to.
•Work with different Reference Point Settings - how to.
•MultiZone Production - how to.
Work with Registration Marks
• A step by step workflow.
System Setup
• Settings specifying the general behaviour of the system.
Tool Configuration and Adjustment
• General information about the tooling and adjustment of tools.
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Kongsberg C-series
Tooling System
• Tool descriptions.
Maintenance
• This chapter describes maintenance to be carried out by the customer.
Fuse Replacement
• Fuse location and specification.
Appendices
•Roll Feeder - basic information.
•Vacuum Cleaner - basic information.
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.
OK The bold style indicates this is a button or function in
the GUI.
Maintenance Link to topic.
Menu Bar->Edit-> Options
Menu selection: From Menu Bar, select Edit and then
Options.
This symbol indicates that the function depends upon
actual hardware.
If hardware is not available, this functions is hidden.
This symbol indicates that the function is license
dependant.
4.3. Pictures and Illustrations
Orientation
In this document, pictures and illustrations related to the Cutting Table are viewed as shown
here:
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4Kongsberg C-series
4.4. Local Languages
This manual is available in a wide range of local languages.
Screen pictures and illustrations remains in English language.
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Kongsberg C-series
5. Safety Regulations
5.1. Introduction
The C-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.
In addition to the Safety Regulation described below, you will find 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 Customer
The Customer is responsible for:
• Ensuring that the system is used for it's Intended Use only
• Allowing that only authorized and trained personnel operate the system
• Preventive maintenance as described in the Maintenance chapter.
• That the Local Regulations regarding installation and operation are fulfilled.
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.
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5Kongsberg C-series
• 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.
5.4. Definition of Use
Intended use is described in the User Manual for i-cut Production Console.
In this manual, Intended use is described in the following chapters:
•Basic Operations
•Prepare for a Job
•How to Procedures, Advanced
Any other use is considered 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.)
• 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.

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5.5. Warning Sign Explanation
Knife Blades are extremely sharp.
This symbol is used in this documentation to indicate operations with
Knife Blades and Milling bits.
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.
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.
• Tool head(s).
Do not Touch
Potential areas with a risk of being squeezed are marked with the Do
Not Touch sign.
These areas are:
• Between Y carriage and rack
• Between the table top and the moving traverse.
• Underneath the tool head.
Hearing Protection
The Hearing Protection symbol indicates areas where the use of
hearing protection is compulsory.
Eye Protection
The Eye Protection symbol indicates areas where the use of eye
protection is compulsory.
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5Kongsberg C-series
The Main Power Unit (MPU) contains Mains Voltage and
may be opened by Authorized Personnel only.
The MPU is marked with the High Voltage warning sign.
Laser Radiation.
The tool head is equipped with a class II Laser Pointer.
Avoid laser light into your eyes.
Do not push or pull traverse beam
Use Manual Jog functions to move the
traverse.
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5.6. Attention Areas
5.6.1. Moving Parts, Laser Radiation and High Voltage
5.6.2. Loose Clothing
While working with this machine, do not:
• Use ties
• Use loose necklaces
• Use scarfs
5.6.3. Noise Level
•Hearing Protection should be used by any personnel exposed to the
noise from the machine.
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5Kongsberg C-series
5.6.4. Ejection of Parts
Potential risk when running HPMU
Personnel hit by breaking milling bit or small pieces of processed material.
•Eye Protection should be used by any
personnel working with HPMU.
5.6.5. i-Camera strobing light
If your system includes i-Camera, please read this warning carefully:
WARNING
i-Camera is equipped with LED strobing light.
The LED default frequency (10 Hz) is in a range that
can cause photosensitive epileptic reactions amongst
susceptible people.
If a person is known to be susceptible, the frame rate,
frequency of strobing, can be reduced to as low as 1 Hz
from the camera configuration menu.
At that rate, seizures are not known to happen.
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