Esko Kongsberg XL User manual

Kongsberg XL
User Manual
09 - 2020 | XL

Kongsberg XL
Contents
1. Preface.........................................................................................................................................................7
2. Change Record........................................................................................................................................... 8
3. Introduction................................................................................................................................................9
3.1. Welcome.............................................................................................................................................9
3.2. FCC conformity statement................................................................................................................9
4. Using this manual................................................................................................................................... 10
4.1. Main Sections.................................................................................................................................. 10
4.2. Name Styles and Symbols..............................................................................................................11
4.3. Pictures and Illustrations................................................................................................................11
4.4. Local Languages..............................................................................................................................11
5. Safety Regulations.................................................................................................................................. 12
5.1. Introduction..................................................................................................................................... 12
5.2. Responsibilities................................................................................................................................12
5.2.1. The Manufacturer................................................................................................................. 12
5.2.2. The owner..............................................................................................................................12
5.2.3. The Operators....................................................................................................................... 12
5.3. Requirements to be met by operators......................................................................................... 13
5.4. Definition of use............................................................................................................................. 13
5.5. Warning sign explanation...............................................................................................................14
5.6. Attention Areas................................................................................................................................17
5.6.1. Danger Zones........................................................................................................................17
5.6.2. Moving Parts, Laser Radiation and High Voltage............................................................... 17
5.6.3. Loose Clothing...................................................................................................................... 17
5.6.4. Noise Level............................................................................................................................ 17
5.6.5. Ejection of parts when milling.............................................................................................18
5.6.6. Milling stop time................................................................................................................... 18
5.6.7. i-Camera strobing light.........................................................................................................18
5.7. Safety devices.................................................................................................................................. 19
5.7.1. Overview................................................................................................................................ 19
5.7.2. Emergency Stop Button....................................................................................................... 19
5.7.3. Warning lamps on Y carriage.............................................................................................. 19
5.7.4. DynaGuard Safety System................................................................................................... 20
5.8. Protective equipment..................................................................................................................... 20
5.9. Procedures in case of malfunctions..............................................................................................21
5.10. Check before operation................................................................................................................21
5.11. Residual Risk,.................................................................................................................................22
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Contents
6. System Description................................................................................................................................. 25
6.1. Naming conventions....................................................................................................................... 25
6.2. Main Power Switch......................................................................................................................... 25
6.3. Operators Panel.............................................................................................................................. 25
6.4. Variable Blow Back..........................................................................................................................27
6.5. Pressurized Air system................................................................................................................... 28
6.6. Application programs available..................................................................................................... 28
7. Basic Operations..................................................................................................................................... 29
7.1. Power On Sequence....................................................................................................................... 29
7.2. Reset Safety System........................................................................................................................30
7.3. Power Off Sequence....................................................................................................................... 30
7.4. Continue after Safety Break...........................................................................................................31
8. Prepare for a Job..................................................................................................................................... 32
8.1. Introduction..................................................................................................................................... 32
8.2. Main Reference Point in iPC.......................................................................................................... 32
8.3. Create Job........................................................................................................................................ 34
8.4. Layer Setup......................................................................................................................................34
8.5. Production Setup............................................................................................................................ 34
8.6. Speed Setting...................................................................................................................................35
8.7. Flute/Grain Direction.......................................................................................................................35
8.8. Vacuum Zone Selection.................................................................................................................. 35
8.9. Job Execution................................................................................................................................... 36
8.10. Milling Production......................................................................................................................... 36
8.11. Make a Pen Plot............................................................................................................................ 37
8.12. Work with X-Pad............................................................................................................................37
9. How To Procedures, Advanced............................................................................................................. 41
9.1. Cutting Thick Materials...................................................................................................................41
9.2. Hard Board Production.................................................................................................................. 41
9.3. Multi Pass Milling............................................................................................................................ 42
9.4. Job including Reverse Operation................................................................................................... 42
9.4.1. Reverse Operation by Left and Right Rulers...................................................................... 43
9.4.2. Reverse Operation by use of Camera.................................................................................44
9.4.3. Reverse Operation in combination with Step and Repeat................................................ 45
9.5. Work with different Reference Point Settings.............................................................................. 45
10. System Setup......................................................................................................................................... 47
10.1. Introduction................................................................................................................................... 47
10.2. Adjust X1 to X2 Angle................................................................................................................... 48
10.3. Register Table Size........................................................................................................................ 48
10.4. Set Ruler Position..........................................................................................................................49
10.5. Set Main Reference Point.............................................................................................................49
10.6. Map Table Top Surface.................................................................................................................49
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Kongsberg XL
10.7. Reference Points and Coordinate System.................................................................................. 50
10.8. Table Speed................................................................................................................................... 51
10.9. Table Acceleration......................................................................................................................... 52
10.10. Jog Settings.................................................................................................................................. 52
10.11. Set Table Top Reference.............................................................................................................52
10.12. Milling Unit Setup....................................................................................................................... 53
10.13. Board Size....................................................................................................................................54
11. Tool Configuration and Adjustment.................................................................................................. 55
11.1. Introduction................................................................................................................................... 55
11.2. Adjust Active Tool..........................................................................................................................55
11.3. Tool Height Calibration.................................................................................................................56
11.4. Lag Settings (for Rotating Tools)..................................................................................................56
11.5. Rotation Adjustment (for Rotating tools)....................................................................................58
11.6. Center Offset Adjustment............................................................................................................ 59
11.7. Manual adjustment of Center Offset and angle........................................................................ 60
11.8. Tool Offset..................................................................................................................................... 60
11.9. Maintain Tool List (More...)...........................................................................................................61
12. Tooling System.......................................................................................................................................63
12.1. Tool handling and care.................................................................................................................63
12.2. Tool Inserts with built-in motor...................................................................................................63
12.3. Tool Heads available, overview....................................................................................................64
12.4. Tool Head mount / dismount...................................................................................................... 65
12.5. FlexiHead........................................................................................................................................65
12.6. PowerHead.................................................................................................................................... 66
12.6.1. ø150 mm Crease Wheel.....................................................................................................67
12.6.2. Crease Adapter ø26 mm....................................................................................................68
12.6.3. Perforation Wheel ø60 mm............................................................................................... 69
12.6.4. HD Knife Tool...................................................................................................................... 70
12.6.5. V-notch Knife.......................................................................................................................71
12.6.6. Bevel Knife 45..................................................................................................................... 77
12.7. FoamHead......................................................................................................................................78
12.8. MultiCUT.........................................................................................................................................80
12.8.1. Introduction.........................................................................................................................80
12.8.2. Tool Head description........................................................................................................ 82
12.8.3. Safety issues........................................................................................................................83
12.8.4. Precautions..........................................................................................................................85
12.8.5. Milling advice.......................................................................................................................89
12.8.6. Bits and Bit Change............................................................................................................92
12.8.7. Chuck Change and Cleaning..............................................................................................95
12.8.8. Bit Slipping, Chuck Change................................................................................................ 99
12.8.9. Bit Length and Position......................................................................................................99
12.8.10. False Air valve................................................................................................................. 100
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Contents
12.8.11. Tool Adjustment..............................................................................................................100
12.8.12. Table Top and Height Adjustment................................................................................ 101
12.8.13. Miscellaneous..................................................................................................................102
12.9. Chiller no 1 (blue top) for MultiCUT-HP....................................................................................103
12.9.1. Introduction.......................................................................................................................103
12.9.2. Chiller, Error Conditions...................................................................................................104
12.9.3. Chiller Heater, Operation.................................................................................................104
12.10. Chiller 2016 / Chiller 2020 for MultiCUT-HP........................................................................... 106
12.10.1. Introduction.....................................................................................................................106
12.10.2. Startup............................................................................................................................. 107
12.10.3. Error Conditions............................................................................................................. 107
12.11. Measuring Foot......................................................................................................................... 108
12.12. Laser Pointer............................................................................................................................. 109
12.13. X-Pad.......................................................................................................................................... 110
12.13.1. X-Pad Calibration............................................................................................................ 110
12.13.2. Tool Depth and X-Pad.................................................................................................... 111
12.13.3. Limitations.......................................................................................................................111
13. Tool inserts........................................................................................................................................... 112
13.1. Ball Point Pen..............................................................................................................................112
13.2. Bevel Knife................................................................................................................................... 113
13.3. Bevel Knife U20...........................................................................................................................114
13.4. Braille Tool................................................................................................................................... 114
13.5. CorruSpeed Knife........................................................................................................................119
13.5.1. Tool adjustment................................................................................................................ 121
13.6. Crease Tool.................................................................................................................................. 122
13.6.1. Tool adjustment................................................................................................................ 122
13.7. Crease Tool, 60 mm....................................................................................................................123
13.7.1. Tool adjustment................................................................................................................ 123
13.8. Drill tools..................................................................................................................................... 124
13.8.1. Flexi Drill Tool....................................................................................................................124
13.8.2. Reboard Drill Tool.............................................................................................................125
13.8.3. Drill Bit dimensions.......................................................................................................... 125
13.8.4. Tool Adjustment................................................................................................................126
13.8.5. Drill Tool in ArtiosCAD......................................................................................................126
13.9. Foam Knife...................................................................................................................................126
13.10. Ink Tool...................................................................................................................................... 127
13.10.1. Liquid Ink Tool................................................................................................................ 127
13.10.2. Fibertip Tool.................................................................................................................... 128
13.10.3. Tool adjustment..............................................................................................................128
13.11. KissCut........................................................................................................................................129
13.12. MicroCut.....................................................................................................................................131
13.13. Psaligraphy Knife.......................................................................................................................133
13.13.1. Tool adjustment..............................................................................................................134
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Kongsberg XL
13.14. RBI 90-16 (Rigid Board Insert)................................................................................................. 134
13.15. Reciprocating Knife................................................................................................................... 135
13.15.1. Tool adjustment..............................................................................................................137
13.16. Rigid Material Knife.................................................................................................................. 137
13.17. RotaCut...................................................................................................................................... 139
13.18. Static Knife.................................................................................................................................142
13.18.1. Tool adjustment..............................................................................................................143
13.19. VI30-16 Knife Tool..................................................................................................................... 143
13.19.1. VIxx Knife Tool, Mounting/Adjustment......................................................................... 144
13.20. VI45 Knife Tool.......................................................................................................................... 145
13.20.1. VIxx Knife Tool, Mounting/Adjustment......................................................................... 145
13.21. VI45-10/12 Knife Tool................................................................................................................147
13.21.1. VIxx Knife Tool, Mounting/Adjustment......................................................................... 147
14. Maintenance........................................................................................................................................ 150
14.1. Daily maintenance...................................................................................................................... 150
14.2. Weekly maintenance...................................................................................................................150
14.3. Maintenance, external equipment............................................................................................ 150
15. Fuse Replacement...............................................................................................................................151
15.1. MPU fuses....................................................................................................................................151
15.2. X1 fuses........................................................................................................................................152
15.3. X2 fuses........................................................................................................................................152
15.4. Y/Z fuses...................................................................................................................................... 153
15.5. Tool Rotation/Reciprocating knife fuses................................................................................... 154
15.6. Sound Insulating Box, Circuit Breaker for fan.......................................................................... 155
16. Vacuum Cleaner.................................................................................................................................. 156
16.1. Vacuum Cleaner, Zefiro.............................................................................................................. 156
16.1.1. How to use........................................................................................................................ 156
16.2. Vacuum Cleaner, High-capacity, TB ESKO.................................................................................158
16.2.1. How to use........................................................................................................................ 158
16.3. Compact Vacuum Cleaner..........................................................................................................161
16.3.1. How to use........................................................................................................................ 161
17. Install Software................................................................................................................................... 163
18. Frequently Asked Questions.............................................................................................................164
18.1. Machine........................................................................................................................................164
18.2. Tools............................................................................................................................................. 165
18.3. iPC.................................................................................................................................................166
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1
Kongsberg XL
1. Preface
User Manual
for
Kongsberg XL
running i-cut Production Console
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.
©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
Document no: D3625
Part no: 32597601
Esko-Graphics Kongsberg AS
www.esko.com
P.O.Box 1016, NO-3601 Kongsberg, NORWAY
Tel.: [phone]
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2Kongsberg XL
2. Change Record
Date
dd-mm-yy
By Description
30-05-2017 jhbe For XL, this is the first edition.
30-05-2017 jhbe Work space limitation when using V-notch or
Bevel knife, information added.
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Kongsberg XL
3. Introduction
3.1. Welcome
Welcome to the User Manual for Kongsberg XL-series running iPC 2.0.
This manual will provide a complete and detailed description of Cutting Table functions.
There is a separate user manual for i-cut Production Console (iPC).
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.
3.2. FCC conformity statement
This machine complies with CFR 47 part 15 of the FCC Rules. Operation is subject to the
following two conditions:
1. This device may not cause harmful interference
2. This device must accept any interference received, including interference that may cause
undesired operation
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4Kongsberg XL
4. Using this manual
4.1. Main Sections
The manual is divided into the following Main Sections:
Safety Regulations
• All safety related issues are discussed.
System Description
• This chapter provides basic knowledge about the machine.
Basic Operations
• 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 Milling - how to.
Tool Configuration and Adjustment
• General information about the tooling and adjustment of tools.
Tooling System
• Tool descriptions.
Maintenance
• This chapter describes maintenance to be carried out by the customer.
Fuse Replacement
• Fuse location and specification.
Appendices
•Vacuum Cleaner - basic information.
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Kongsberg XL
•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.
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
Pictures and illustrations related to the Cutting Table are viewed as illustated here:
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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5Kongsberg XL
5. Safety Regulations
5.1. Introduction
The table is designed to conform to Safety Regulation standards.
Nevertheless, operating the table can involve hazards if:
• The operator does not follow the Operating Instructions.
• The table is used for Non-intended purposes.
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 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
• 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:
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Kongsberg XL
• 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.
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.)
• Deliberately avoiding the DynaGuard safety system by reaching under the lower beam to
avoid detection.
• 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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5Kongsberg XL
5.5. Warning sign explanation
High voltage warnings
• Main Power Unit (MPU)
External components are not disconnected by the mains connection of
the cutting table.
Do not remove the cover of this unit until the mains connection for
cutting table, and mains connections for all external components, such
as vacuum pump, vacuum cleaner, IBAG inverter and chiller, have been
removed from the socket outlets. High voltage controlled from external
source inside.
Note: Different instruction for Cxx and Xxx.
• Vacuum pump
The vacuum pump is not disconnected by the mains connection of the
cutting table.
Do not remove the cover of this unit until the mains connection has
been removed from the socket outlet for the vacuum pump.
Note: Different instruction for Cxx and Xxx.
• Vacuum cleaner
The vacuum cleaner is not disconnected by the mains connection of the
cutting table.
Do not remove the cover of this unit until the mains connection has
been removed from the socket outlet for the vacuum cleaner.
Note: Different instruction for Cxx and Xxx.
• IBAG inverter
The IBAG inverter is not disconnected by the mains connection of the
cutting table.
Do not remove the cover of this unit until the mains connection has
been removed from the socket outlet for the IBAG inverter.
Note: Different instruction for Cxx and Xxx.
• Chiller
The chiller is not disconnected by the mains connection of the cutting
table.
Do not remove the cover of this unit until the mains connection has
been removed from the socket outlet for the chiller.
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Kongsberg XL
Note: Different instruction for Cxx and Xxx.
• Starter unit
The starter unit is not disconnected by the mains connection of the
cutting table only.
Do not remove the cover of this unit until the mains connections have
been removed from the socket outlet for vacuum pump, vacuum
cleaner, IBAG inverter and chiller, in addition to the cutting table.
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
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:
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5Kongsberg XL
• Between X-axis end stopper and traverse wagon.
Moving Parts
Potential areas with a risk of being hit by Moving Parts are marked with
the Moving Parts sign.
These areas are:
• Both traverse ends.
• Y carriage.
• 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.
Do not leave the machine running if the vacuum
cleaner can be over-filled. This might cause damage, or
in worst case a fire if the suction house is clogged.
See also Safety issues on page 83 in the section for
milling.
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Kongsberg XL
5.6. Attention Areas
5.6.1. Danger Zones
The area around the moving parts is considered to be a Danger Zone.
The Danger Zone is identified by the means of a yellow / black floor marking.
5.6.2. Moving Parts, Laser Radiation and High Voltage
5.6.3. Loose Clothing
While working with this machine, do not:
• Use ties
• Use loose necklaces
• Use scarfs
5.6.4. Noise Level
•Hearing Protection should be used by any personnel exposed to the
noise from the machine.
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5Kongsberg XL
5.6.5. Ejection of parts when milling
Ejection of parts is a potentional risk when milling. Always use eye protection
to prevent injury from breaking milling bits or small pieces of processed
material.
See also Safety issues on page 83 in the section for milling.
5.6.6. Milling stop time
The milling spindle does not stop instantly.
Always ensure that the red lamp has stopped
flashing, and by visual inspection that the
milling bit has come to a complete standstill
before touching it.
Note: Only specially trained operators are
allowed to operate milling tools.
5.6.7. 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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Kongsberg XL
5.7. Safety devices
5.7.1. Overview
Device no Description
1Main Power Switch
2Emergency Stop Button
3 Warning lamp/status lamp (Y carriage) / milling spindle running (milling unit)
4Photo cell supervision, Dynaguard
5Traverse Stop Switches, Dynaguard
5.7.2. 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. (On
machines before approx. 2020, Mains Power to the machine is switched off).
Note:
Activating the Emergency Stop Button does not provide a guarantee against injury!
Due to the high kinetic energy of moving parts, do not underestimate Stop Distance of
traverse, Y carriage and Tool Head.
5.7.3. Warning lamps on Y carriage
Light is Description, Y carriage
Off Servo Power is off
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5Kongsberg XL
Light is Description, Y carriage
On Servo Power is on, Safety System is enabled, table is in operation
Flashing Safety System is activated.
Reset Safety System to continue operation
Light is Description, milling unit
Off Milling spindle not running
On Milling spindle running
Flashing Milling spindle running (starting or stopping)
5.7.4. 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.
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.
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