Esko Kongsberg XE10 User manual

Kongsberg XE
User Manual
09 - 2017 | Kongsberg XE

Kongsberg XE
Contents
1. Preface......................................................................................................................................................... 7
2. Change Record........................................................................................................................................... 8
3. Welcome...................................................................................................................................................... 9
4. Using this manual................................................................................................................................... 10
4.1 Main Sections................................................................................................................................... 10
4.2 Name Styles and Symbols...............................................................................................................11
4.3 Pictures and Illustrations.................................................................................................................11
4.4 Local Languages............................................................................................................................... 12
4.5 About Xx-Guide dialogs................................................................................................................... 12
5. Safety Regulations.................................................................................................................................. 13
5.1 Introduction...................................................................................................................................... 13
5.2 Responsibilities................................................................................................................................. 13
5.2.1 The Manufacturer.................................................................................................................. 13
5.2.2 The Customer.........................................................................................................................13
5.2.3 The Operators........................................................................................................................ 13
5.3 Requirements to be met by Operators..........................................................................................14
5.4 Definition of Use.............................................................................................................................. 14
5.5 Danger Zones................................................................................................................................... 14
5.5.1 Danger Zones.........................................................................................................................14
5.5.2 Moving Parts, Laser Radiation and High Voltage................................................................ 15
5.5.3 Loose Clothing........................................................................................................................15
5.5.4 Noise Level............................................................................................................................. 16
5.6 Warning Sign Explanation............................................................................................................... 16
5.7 Safety devices................................................................................................................................... 17
5.7.1 Overview................................................................................................................................. 17
5.7.2 Main Power Switch................................................................................................................ 18
5.7.3 Emergency Stop Button........................................................................................................ 18
5.7.4 Warning Lamp on top of Y Carriage.................................................................................... 19
5.7.5 DynaGuard Safety System.................................................................................................... 19
5.8 Protective Equipment.......................................................................................................................20
5.9 Procedures in case of Malfunctions............................................................................................... 20
5.10 Residual Risk...................................................................................................................................20
6. System Description, XE.......................................................................................................................... 23
6.1 Introduction...................................................................................................................................... 23
6.2 Naming conventions........................................................................................................................ 23
6.3 Main Power Switch...........................................................................................................................24
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6.4 Operators Panel............................................................................................................................... 24
6.5 Pressurized Air system.................................................................................................................... 26
6.6 Application programs available.......................................................................................................27
7. XE-Guide.................................................................................................................................................... 28
7.1 The Graphical User Interface.......................................................................................................... 28
7.2 The Main Menu................................................................................................................................ 28
7.3 The Main Toolbar functions............................................................................................................ 30
7.4 File View............................................................................................................................................ 31
7.5 File View toolbar...............................................................................................................................32
7.6 Job View.............................................................................................................................................34
7.7 Job View toolbar............................................................................................................................... 35
7.8 Preview.............................................................................................................................................. 37
7.9 Status bar..........................................................................................................................................37
7.10 Critical Warning Display.................................................................................................................38
7.11 Message Display.............................................................................................................................38
7.12 Position Display..............................................................................................................................39
7.13 Accelerator Keys............................................................................................................................. 40
8. Basic Operations......................................................................................................................................42
8.1 Introduction...................................................................................................................................... 42
8.2 Power On Sequence........................................................................................................................ 42
8.3 Reset Safety System.........................................................................................................................43
8.4 Power Off Sequence........................................................................................................................ 43
8.5 Continue after Safety Break............................................................................................................44
9. Prepare for a Job..................................................................................................................................... 45
9.1 Introduction...................................................................................................................................... 45
9.2 Job Setup...........................................................................................................................................45
9.3 Board Setup......................................................................................................................................46
9.4 Open an input file............................................................................................................................46
9.5 Flute/Grain Direction........................................................................................................................47
9.6 Vacuum Section Selection............................................................................................................... 47
9.7 Speed Setting....................................................................................................................................47
9.8 Job Execution.................................................................................................................................... 48
9.9 Corrugated production.................................................................................................................... 48
9.10 Folded Carton Production............................................................................................................. 49
9.11 Make a Pen Plot............................................................................................................................. 50
10. How To Procedures, Advanced........................................................................................................... 51
10.1 Jobs including Reverse Score........................................................................................................ 51
10.2 Different Reference Point settings............................................................................................... 52
10.3 Change Tool in a Job......................................................................................................................52
10.4 Work with Register Bar..................................................................................................................53
11. System Setup..........................................................................................................................................56
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11.1 Introduction.................................................................................................................................... 56
11.2 Speed Setup....................................................................................................................................57
11.3 Table Acceleration.......................................................................................................................... 57
11.4 Table Speed.................................................................................................................................... 57
11.5 Jog Settings..................................................................................................................................... 58
11.6 Table Setup..................................................................................................................................... 58
11.7 Set Reference Point....................................................................................................................... 59
11.8 Set Ruler Position...........................................................................................................................60
11.9 Set Table Top Reference................................................................................................................60
11.10 Map Table Top Surface................................................................................................................61
11.11 Register Table Size....................................................................................................................... 61
11.12 Adjust X1 to X2 Angle.................................................................................................................. 61
11.13 Vacuum Control............................................................................................................................62
11.14 System Options............................................................................................................................ 63
11.15 Display Units.................................................................................................................................64
11.16 Language.......................................................................................................................................64
11.17 Input File....................................................................................................................................... 64
11.18 Optimization................................................................................................................................. 66
11.19 Vacuum Setup.............................................................................................................................. 67
11.19.1 Vacuum Section Configuration......................................................................................... 67
11.20 Park Position.................................................................................................................................67
11.21 Display Color................................................................................................................................ 68
11.22 Board Size.....................................................................................................................................68
11.23 Change Flute/grain direction.......................................................................................................69
11.24 Transformations........................................................................................................................... 69
11.25 Step and Repeat...........................................................................................................................71
11.26 Counter setup dialog................................................................................................................... 73
12. Reference Points and Coordinate System........................................................................................ 75
13. Job Setup................................................................................................................................................. 78
13.1 Introduction.................................................................................................................................... 78
13.2 Select Job Setup files..................................................................................................................... 78
13.3 Create and edit Job Setup files..................................................................................................... 78
13.4 Job Setup Parameters....................................................................................................................79
13.5 Extended......................................................................................................................................... 81
13.6 More................................................................................................................................................ 82
14. Job Layout...............................................................................................................................................85
14.1 Introduction.................................................................................................................................... 85
14.2 Multi design layout functions....................................................................................................... 85
14.3 Job Layout Setup............................................................................................................................ 86
15. Tool Configuration and Adjustment.................................................................................................. 88
15.1 Combination of Tools.................................................................................................................... 88
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15.2 Tool Configuration..........................................................................................................................88
15.3 Adjust Active Tool...........................................................................................................................89
15.4 Lag Settings (for Rotating Tools)...................................................................................................90
15.5 Tool Height Calibration.................................................................................................................. 92
15.6 Rotation Adjustment (for Rotating tools).....................................................................................92
15.7 Center Offset Adjustment............................................................................................................. 93
15.8 Manual adjustment of Center Offset and angle......................................................................... 94
15.9 Tool Offset...................................................................................................................................... 95
15.10 Maintain Tool List (More...)..........................................................................................................96
16. Tooling System....................................................................................................................................... 97
16.1 Introduction.................................................................................................................................... 97
16.2 Tool Handling and Care.................................................................................................................97
16.3 How to Replace a Tool...................................................................................................................98
16.4 Two or more tools of the same type........................................................................................... 98
16.5 PressCut Knife Tool......................................................................................................................100
16.6 Static Knife Tool............................................................................................................................103
16.7 VibraCut Knife Tool...................................................................................................................... 104
16.8 VariCut Knife Tool........................................................................................................................ 107
16.9 Hi-Force Knife Tool.......................................................................................................................111
16.10 Psaligraphy Knife........................................................................................................................113
16.11 RotaCut Knife Tool..................................................................................................................... 114
16.12 Multi-Function Unit.................................................................................................................... 118
16.13 Ballpoint Pen / Ink Tool............................................................................................................. 118
16.14 Measuring Foot.......................................................................................................................... 120
16.15 Laser Pointer.............................................................................................................................. 121
16.16 i-cut camera................................................................................................................................121
17. Maintenance.........................................................................................................................................122
17.1 Daily maintenance....................................................................................................................... 122
17.2 Weekly maintenance....................................................................................................................122
17.3 Maintenance, external equipment............................................................................................. 122
18. Fuse replacement................................................................................................................................123
18.1 MPU............................................................................................................................................... 123
18.2 X1................................................................................................................................................... 125
18.3 X2................................................................................................................................................... 126
18.4 Y/Z fuse......................................................................................................................................... 126
18.5 Tool Rotation/Reciprocating knife/Tool up_down......................................................................127
19. Install software....................................................................................................................................130
20. Frequently Asked Questions............................................................................................................. 131
20.1 Machine.........................................................................................................................................131
20.2 Tools.............................................................................................................................................. 131
20.3 Xx-Guide........................................................................................................................................132
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20.4 i-cut................................................................................................................................................133
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1. Preface
User Manual
for
Kongsberg XE / i-XE
Serial no ____________
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 2017, 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: D3532
Part no: 32599524
Esko-Graphics Kongsberg AS
www.esko.com
P.O.Box 1016, N-3601 Kongsberg, Norway
Tel: [phone] Fax: [phone]
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2. Change Record
Date
dd-mm-yy
By Description
09-02-2014 jhbe First edition of this document
12-01-2017 JHBE Updated version of this document
13-06-2017 jhbe Psaligraphy Knife tool added
05-09-2017 jhbe PressCut chapter updated.
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3. Welcome
Welcome to the User Manual for Kongsberg XE / i-XE.
This manual will provide a complete and detailed description of all XE / i-XE functions.
It is aimed for operators of Kongsberg Cutting Tables and people preparing files for such
equipment.
Note: Some of the functions and equipments described in this manual are optional.
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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:
•Multi Pass Creasing - how to.
• Jobs including Reverse Score - how to.
• Work with different Reference Point Settings - how to.
•Forced Tool Height Measurement - how to.
System Setup
• Settings specifying the general behaviour of the system.
Tool Configuration and Adjustment
• General information about the tooling and adjustment of tools.
Tooling System
• Tool descriptions.
Maintenance
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• This chapter describes maintenance to be carried out by the customer.
Fuse Replacement
• Fuse location and specification.
Appendices
• FAQ - Frequently Asked Questions
4.2 Name Styles and Symbols
Name or style Description
Pop-up dialog This is the dialog that appears when you click the Right
mouse button.
Start button The italic style indicates this is a button on the Operator
panel.
OK The bold style indicates this is a button or function in
the GUI.
Maintenance Link to topic.
Options->System Option
Menu selection: From the Options menu, select System
Option.
4.3 Pictures and Illustrations
Orientation
Pictures and illustrations related to the Cutting Table are viewed as illustated here:
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4.4 Local Languages
This manual is available in a wide range of local languages.
Screen pictures and illustrations remains in English language.
4.5 About Xx-Guide dialogs
To exit from any Xx-Guide dialog, use the control buttons available.
Using the cross in upper right corner is not recommended and the consequence is un-
predictable.
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5. Safety Regulations
5.1 Introduction
The table is designed to conform to Safety Regulation standards.
Nevertheless, operating the table can involve hazards if:
• The operator does not follow the Operating Instructions.
• The table is used for Non-intended purposes.
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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• 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
The 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.

5.5 Danger Zones
5.5.1 Danger Zones
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The area around the moving parts is considered to be a Danger Zone.
The Danger Zone is identified by the means of a yellow / black floor marking.
5.5.2 Moving Parts, Laser Radiation and High Voltage
5.5.3 Loose Clothing
While working with this machine, do not:
• Use ties
• Use loose necklaces
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• Use scarfs
5.5.4 Noise Level
•Hearing Protection should be used by any personnel exposed to the noise
from the machine.
5.6 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.
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.
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Eye Protection
The Eye Protection symbol indicates areas where the use of eye
protection is compulsory.
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).
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.
5.7 Safety devices
5.7.1 Overview
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Device no Description
1Main Power Switch
2Emergency Stop Button
3Warning Lamp / Status Lamp
4Photo cell supervision, Dynaguard
5Traverse Stop Switches, Dynaguard
5.7.2 Main Power Switch
The Main Power Switch turns power to the table on/off.
5.7.3 Emergency Stop Button
Switch positions:
OUT - Emergency Stop is switched OFF. 
IN - Emergency Stop is switched ON; Servo Power to the machine is switched off.
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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 Stop Distance of
traverse, Y carriage and Tool Head.
5.7.4 Warning Lamp on top of Y Carriage
Light is Description
Off Servo Power is off
On Servo Power is on, Safety System is enabled, table is in operation
Flashing Safety System is activated.
Reset Safety System to continue operation
5.7.5 DynaGuard Safety System
The DynaGuard Safety System consists of two light beams in front of the traverse and one
behind.
In addition, there is a stop mechanism mounted on each end of the traverse.
Machine movement will stop and Servo Power will be switched off if:
• One of the light beams are broken.
• The stop mechanism is activated, for instance when a person is standing too near the table.
Continue after DynaGuard is triggered
To continue operation, proceed as follows:
1. Ensure the table is free from obstructions and ready for operation.
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2. Reset the Safety System by pressing the Pause pushbutton.
3. Observe that Servo Power is switched on,
4. Press Start to continue.
5.8 Protective Equipment
For the operator(s), Esko recommends the following Protective Equipment:
Close-fitting clothes to avoid being caught by the beam or the tool head
which can cause injuries.
Gloves to protect against cuts from materials with sharp edges.
Eye protection should be used by any personnel working with milling.
Always use Hearing Protection when working with the machine for a
longer period of time.
The acoustic noise level will vary with the type of operation and tooling,
but a typical average level is 78.5 – 83.5 dBA and a maximum level of
98.5 dBA.
5.9 Procedures in case of Malfunctions
Trouble-shooting and repair shall be executed by Authorized Personnel only.
Contact the Esko Service Organization.
5.10 Residual Risk
Despite all safety protection means incorporated in this machine, there are some Residual
Safety Risks to be aware of:
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