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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3
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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