Esko Kongsberg XN Operating instructions

XN
Site Preparation Manual

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Contents
1. Preface..............................................................................................................................................................................................5
2. Change record...............................................................................................................................................................................6
3. Introduction.....................................................................................................................................................................................7
3.1 Welcome................................................................................................................................................................................7
3.2 About Installation...............................................................................................................................................................7
4. Receiving Equipment from Esko.......................................................................................................................................... 9
4.1 Inspection of Equipment................................................................................................................................................ 9
4.2 Temporary Storage............................................................................................................................................................9
4.3 System Label.......................................................................................................................................................................9
4.4 Table Transport.................................................................................................................................................................10
5. Packaging Specification.........................................................................................................................................................12
5.1 XN20, Packaging.............................................................................................................................................................12
5.2 XN22, Packaging.............................................................................................................................................................12
5.3 XN24, Packaging.............................................................................................................................................................13
5.4 XN40, Packaging.............................................................................................................................................................14
5.5 XN44, Packaging.............................................................................................................................................................14
5.6 XN46, Packaging.............................................................................................................................................................15
5.7 XN48, Packaging.............................................................................................................................................................16
6. Room Preparation..................................................................................................................................................................... 18
6.1 About Room Preparation............................................................................................................................................. 18
6.2 Floor Covering..................................................................................................................................................................18
6.3 Furniture..............................................................................................................................................................................18
6.4 Material Storage.............................................................................................................................................................. 18
6.5 Workflow............................................................................................................................................................................. 18
6.6 Floor Load and Level.................................................................................................................................................... 19
6.7 Computer Floor................................................................................................................................................................19
6.8 Headroom...........................................................................................................................................................................19
6.9 Noise Level........................................................................................................................................................................ 20
7. DynaGuard Safety System....................................................................................................................................................21
8. System Layout............................................................................................................................................................................22
8.1 Introduction........................................................................................................................................................................23
8.2 Recommended Layout..................................................................................................................................................23
9. Cables, Hoses and Fuses..................................................................................................................................................... 25
9.1 Symbols used in Figures............................................................................................................................................. 27
9.2 Specifications....................................................................................................................................................................28

Contents
iii
10. Tables, Specification............................................................................................................................................................. 30
10.1 XN20.................................................................................................................................................................................. 30
10.2 XN22.................................................................................................................................................................................. 31
10.3 XN24.................................................................................................................................................................................. 33
10.4 XN40.................................................................................................................................................................................. 35
10.5 XN44.................................................................................................................................................................................. 37
10.6 XN46.................................................................................................................................................................................. 38
10.7 XN48.................................................................................................................................................................................. 40
11. XN with Extension Table..................................................................................................................................................... 43
11.1 XN20.................................................................................................................................................................................. 43
11.2 XN22.................................................................................................................................................................................. 44
11.3 XN24.................................................................................................................................................................................. 46
11.4 XN40.................................................................................................................................................................................. 48
11.5 XN44.................................................................................................................................................................................. 49
12. XN with Sheet Feeder.......................................................................................................................................................... 51
12.1 XN20.................................................................................................................................................................................. 51
12.2 XN22.................................................................................................................................................................................. 53
12.3 XN24.................................................................................................................................................................................. 54
12.4 XN40.................................................................................................................................................................................. 55
12.5 XN44.................................................................................................................................................................................. 57
13. Front End PC............................................................................................................................................................................ 59
13.1 Configuration.................................................................................................................................................................. 59
13.2 Requirements..................................................................................................................................................................59
13.3 Specification................................................................................................................................................................... 59
13.4 Dimensions......................................................................................................................................................................60
14. PC Table......................................................................................................................................................................................61
15. Operator Station......................................................................................................................................................................62
16. Roll Feeder.................................................................................................................................................................................64
17. Compressed Air System......................................................................................................................................................65
17.1 General..............................................................................................................................................................................65
17.2 Air Source Outlet.......................................................................................................................................................... 65
17.3 Air Source Specification............................................................................................................................................ 65
17.4 Purchase Compressor................................................................................................................................................ 66
18. Vacuum System....................................................................................................................................................................... 67
18.1 Introduction..................................................................................................................................................................... 67
18.2 Vacuum Pump for Table Models............................................................................................................................67
18.3 Recommended Mains Fuses/Cable Dimensions............................................................................................. 68
18.4 Electrical Solution, Concept.....................................................................................................................................68
18.5 Vacuum Extern Kit, Content.....................................................................................................................................70

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18.6 Technical Information, Vacuum Pumps................................................................................................................70
18.7 Sound Suppression Box for Vacuum Pump......................................................................................................71
19. E-save for Vacuum Pump................................................................................................................................................... 73
19.1 Installation........................................................................................................................................................................73
19.2 Electrical Requirements..............................................................................................................................................74
19.3 Dimensions......................................................................................................................................................................74
20. Cutting Table with Controller.............................................................................................................................................76
20.1 Requirements..................................................................................................................................................................76
20.2 Direct Mains Connection...........................................................................................................................................76
20.3 Ground System..............................................................................................................................................................76
20.4 Un-interruptible Power System...............................................................................................................................76
20.5 Noise Level......................................................................................................................................................................77
21. MultiCUT/MultiCUT HP.........................................................................................................................................................78
21.1 Requirements..................................................................................................................................................................78
21.2 Direct Mains Connection...........................................................................................................................................78
21.3 Pressurized Air requirements...................................................................................................................................78
21.4 PC configuration........................................................................................................................................................... 78
21.5 Noise Level......................................................................................................................................................................78
22. Chiller for MultiCUT HP....................................................................................................................................................... 80
22.1 Requirements..................................................................................................................................................................80
22.2 Direct Mains Connection...........................................................................................................................................80
22.3 Installation........................................................................................................................................................................80
23. Vacuum cleaner for MultiCUT...........................................................................................................................................83
23.1 Requirements..................................................................................................................................................................83
23.2 Direct Mains Connection...........................................................................................................................................83
23.3 Installation........................................................................................................................................................................83
24. Direct Mains Connection, Guidelines............................................................................................................................ 85
25. Site Prep Ready, Check List..............................................................................................................................................86

1
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1. Preface
Site Preparation Manual
for
Kongsberg XN
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 2014, 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: D3278
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
16-03-2014 jhbe First version of the document
28-05-2014 jhbe Packaging information improved.
Dimension drawings and tables has been improved.
All relevant Extension table configurations are now
described.

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3. Introduction
3.1 Welcome
Welcome to a long-lasting co-operation with Esko.
This Site Preparation Manual is intended to provide information about the equipment that you will
receive and how to prepare the site for the installation.
Note: Some of the equipment’s described in this manual are optional.
3.2 About Installation
Before the Service Engineers arrive on-site to install the system, the following items given in this
handbook should be done:
• Prepare the destination room.
• Prepare all electrical supplies.
• Prepare compressed air supply. If an air compressor is delivered from Esko, a suitable place for
the unit should be prepared.
• Prepare a suitable room for the vacuum pump. Due to its acoustic noise, the vacuum pump should
be located in a room away from people. Remember electrical supply for the vacuum pump.
• Bring the crates containing the equipment into the destination room, but do not open.
If properly done, this preparation permits the system to be commissioned as quickly as possible. The
less time spent on the installation, the more time our engineer can spend with department designers
and/or table operator(s) training them on system operation.

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If the customer requires additional information, over and above that given here, the Esko Service
Department will be glad to provide it.
To ensure that no damage occurs to essential parts, Esko Service Engineers must unpack all
equipment.
Under no circumstances must either crates or boxes be opened with crowbars or similar tools,
this can cause damage to the contents.
Immediately after an item is unpacked, it must be inspected carefully for signs of damage. 
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.

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4. Receiving Equipment from Esko
4.1 Inspection of Equipment
In case of visual damage to one or more of the crates upon delivery, a note/remark should be made
on the receipt of the forwarder and the forwarder should be notified.
Shipper shall be informed about the damage, and the signed receipt with remark should be sent to
the shipper.
The signed receipt is very important as proof of damage in case there is damage to the contents of
the shipment for the further processing of the case.
Photos should be made of the damage, preferably before the goods are unloaded from the truck.
The photos need to be sent to the shipper.
The goods are not to be opened without the presence of qualified Esko Service Engineer or
partners.
If damage is found while unpacking the unit, the Service Engineers from Esko need to make photos
of this and sent it to shipper.
4.2 Temporary Storage
While in the crates, store the equipment in a storage room, protected from weather, including direct
sunlight and extreme temperatures.
The storage temperature must be kept within -20° C to +40° C / -4° F to +104° F with humidity less
than 95% RH non-condensing.
4.3 System Label
A System Label as shown below is affixed to the table stand near to the Main Power Unit (sample)

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4.4 Table Transport
Due to its high weight, special attention should be paid to the methods used to bring the table tops
into the destination room.
Typical weights (one table section):
Table Kg lbs
XN20 230 506
XN22 320 700
XN24 230 506
XN4x 265 580
Note:
• Recommendations are valid for all mechanical parts.
• Adhere to Local Regulations regarding lifting safety.
• Adhere to Local Regulations regarding protective equipments, such as protective shoes and
gloves.
Please follow the recommended rules:
• Keep the table top(s) in the wooden crate(s)
as long as possible. While in the case, the
top(s) are protected even if moved vertically.
• Use forklift for lifting.
• Be careful when the table is moved out of the
wooden case.
•Use protection bars to protect the racks.
Minimum height 50 mm / 2 in.; bars are
included in the shipment (picture).
• When lifting, do not lift by the racks or
guides. Use the front and back ends of the
table for lifting as illustrated.
• Be extremely careful not to hit the racks or
guides in any way.
• If the table is moved in vertical position, place
protection bars along the bottom side of the
table.
Note: If installation according to Local Regulations is not possible, a firm of movers should be hired.

4
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5. Packaging Specification
5.1 XN20, Packaging
Metric
Crates Length, L
(cm)
Width, W
(cm)
Height, H
(cm)
Weight (kg) Net weight
(kg)
1. Table (standard) 205 198 36 320 231
2. Traverse (standard) 282 52 100 175 115
3. Frame (standard) 198 132 92 430 350
4. Chiller 100 80 64 90 50
5. Noice reduction box 114 104 86 78 69
6. Air Compressor 120 80 92 87 67
7. Vacuum Cleaner 136 73 150 124 104
Imperial
Crates Length, L
(in)
Width, W (in) Height, H
(in)
Weight (lbs) Net weight
(lbs)
1. Table (standard) 80.7 78.0 14.2 705.6 509.4
2. Traverse (standard) 111.0 20.5 39.4 385.9 253.6
3. Frame (standard) 78.0 52.0 36.2 948.1 771.8
4. Chiller 39.4 31.5 25.2 198.5 110.3
5. Noice reduction box 44.9 40.9 33.9 172.0 152.1
6. Air Compressor 47.2 31.5 36.2 191.8 147.7
7. Vacuum Cleaner 53.5 28.7 59.1 273.4 229.3
5.2 XN22, Packaging
Metric
Crates Length, L
(cm)
Width, W
(cm)
Height, H
(cm)
Weight (kg) Net weight
(kg)
1. Table (standard) 297 198 36 435 320
2. Traverse (standard) 282 52 100 180 120
3. Frame (standard) 205 202 92 500 393
4. Chiller 100 80 64 90 50
5. Noice reduction box 114 104 86 78 69

5
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Crates Length, L
(cm)
Width, W
(cm)
Height, H
(cm)
Weight (kg) Net weight
(kg)
6. Air Compressor 120 80 92 87 67
7. Vacuum Cleaner 136 73 150 124 104
Imperial
Crates Length, L
(in)
Width, W (in) Height, H
(in)
Weight (lbs) Net weight
(lbs)
1. Table (standard) 116,9 78,0 14,2 957,0 704,0
2. Traverse (standard) 111,0 20,5 39,4 396,0 264,0
3. Frame (standard) 80,7 79,5 36,2 1100,0 864,6
4. Chiller 39,4 31,5 25,2 198,0 110,0
5. Noice reduction box 44,9 40,9 33,9 171,6 151,8
6. Air Compressor 47,2 31,5 36,2 191,4 147,4
7. Vacuum Cleaner 53,5 28,7 59,1 272,8 228,8
5.3 XN24, Packaging
Metric
Crates Length, L
(cm)
Width, W
(cm)
Height, H
(cm)
Weight (kg) Net weight
(kg)
1. Table (standard) 205 198 36 320 231
2. Table (standard) 205 198 36 320 231
3. Frame (standard) 198 132 92 360 280
4. Traverse (standard) 282 52 100 200 140
5. Frame (standard) 198 132 92 280 200
6. Chiller 100 80 64 90 50
7. Noise reduction box 114 104 86 78 69
8. Air Compressor 120 80 92 87 67
9. Vacuum Cleaner 136 73 150 124 104
Imperial
Crates Length, L
(in)
Width, W (in) Height, H
(in)
Weight (lbs) Net weight
(lbs)
1. Table (standard) 80,7 78,0 14,2 704,0 508,2
2. Table (standard) 80,7 78,0 14,2 704,0 508,2
3. Frame (standard) 78,0 52,0 36,2 792,0 616,0
4. Traverse (standard) 111,0 20,5 39,4 440,0 308,0
5. Frame (standard) 78,0 52,0 36,2 616,0 440,0
6. Chiller 39,4 31,5 25,2 198,0 110,0

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Crates Length, L
(in)
Width, W (in) Height, H
(in)
Weight (lbs) Net weight
(lbs)
7. Noise reduction box 44,9 40,9 33,9 171,6 151,8
8. Air Compressor 47,2 31,5 36,2 191,4 147,4
9. Vacuum Cleaner 53,5 28,7 59,1 272,8 228,8
5.4 XN40, Packaging
Metric
Crates Length, L
(cm)
Width, W
(cm)
Height, H
(cm)
Weight (kg) Net weight
(kg)
1. Table (standard) 251 205 36 375 273
2. Traverse (standard) 337 52 100 200 132
3. Frame (standard) 251 132 92 430 350
4. Chiller 100 80 64 90 50
5. Noice reduction box 114 104 86 78 69
6. Air Compressor 120 80 92 87 67
7. Vacuum Cleaner 136 73 150 124 104
Imperial
Crates Length, L
(in)
Width, W (in) Height, H
(in)
Weight (lbs) Net weight
(lbs)
1. Table (standard) 98,8 80,7 14,2 825,0 600,6
2. Traverse (standard) 132,7 20,5 39,4 440,0 290,4
3. Frame (standard) 98,8 52,0 36,2 946,0 770,0
4. Chiller 39,4 31,5 25,2 198,0 110,0
5. Noice reduction box 44,9 40,9 33,9 171,6 151,8
6. Air Compressor 47,2 31,5 36,2 191,4 147,4
7. Vacuum Cleaner 53,5 28,7 59,1 272,8 228,8
5.5 XN44, Packaging
Metric
Crates Length, L
(cm)
Width, W
(cm)
Height, H
(cm)
Weight (kg) Net weight
(kg)
1. Table (standard) 251 205 36 375 273
2. Table (standard) 251 205 36 375 273
3. Frame (standard) 251 132 92 450 360

5
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Crates Length, L
(cm)
Width, W
(cm)
Height, H
(cm)
Weight (kg) Net weight
(kg)
4. Traverse (standard) 337 52 100 200 132
5. Frame (standard) 251 132 92 310 210
6. Chiller 100 80 64 90 50
7. Noise reduction box 114 104 86 78 69
8. Air Compressor 120 80 92 87 67
9. Vacuum Cleaner 136 73 150 124 104
Imperial
Crates Length, L
(in)
Width, W (in) Height, H
(in)
Weight (lbs) Net weight
(lbs)
1. Table (standard) 98,8 80,7 14,2 825,0 600,6
2. Table (standard) 98,8 80,7 14,2 825,0 600,6
3. Frame (standard) 98,8 52,0 36,2 990,0 792,0
4. Traverse (standard) 132,7 20,5 39,4 440,0 290,4
5. Frame (standard) 98,8 52,0 36,2 682,0 462,0
6. Chiller 39,4 31,5 25,2 198,0 110,0
7. Noise reduction box 44,9 40,9 33,9 171,6 151,8
8. Air Compressor 47,2 31,5 36,2 191,4 147,4
9. Vacuum Cleaner 53,5 28,7 59,1 272,8 228,8
5.6 XN46, Packaging
Metric
Crates Length, L
(cm)
Width, W
(cm)
Height, H
(cm)
Weight (kg) Net weight
(kg)
1. Table (standard) 251 205 36 375 273
2. Table Mid (standard) 251 172 36 330 245
3. Table (standard) 251 205 36 375 273
4.Traverse (standard) 337 52 100 200 132
5. Frame (standard) 251 132 92 450 360
6. Frame (standard) 251 132 92 310 210
7. Frame (standard) 251 132 92 310 210
8. Chiller 100 80 64 90 50
9. Noice reduction box 114 104 86 78 69
10. Air Compressor 120 80 92 87 67
11. Vacuum Cleaner 136 73 150 124 104

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Imperial
Crates Length, L
(in)
Width, W (in) Height, H
(in)
Weight (lbs) Net weight
(lbs)
1. Table (standard) 98,8 80,7 14,2 825,0 600,6
2. Table Mid (standard) 98,8 67,7 14,2 726,0 539,0
3. Table (standard) 98,8 80,7 14,2 825,0 600,6
4.Traverse (standard) 132,7 20,5 39,4 440,0 290,4
5. Frame (standard) 98,8 52,0 36,2 990,0 792,0
6. Frame (standard) 98,8 52,0 36,2 682,0 462,0
7. Frame (standard) 98,8 52,0 36,2 682,0 462,0
8. Chiller 39,4 31,5 25,2 198,0 110,0
9. Noice reduction box 44,9 40,9 33,9 171,6 151,8
10. Air Compressor 47,2 31,5 36,2 191,4 147,4
11. Vacuum Cleaner 53,5 28,7 59,1 272,8 228,8
5.7 XN48, Packaging
Metric
Crates Length, L
(cm)
Width, W
(cm)
Height, H
(cm)
Weight (kg) Net weight
(kg)
1. Table (standard) 251 205 36 375 273
2. Table Mid (standard) 251 172 36 330 245
3. Table Mid (standard) 251 172 36 330 245
4. Table (standard) 251 205 36 375 273
5. Traverse (standard) 337 52 100 200 132
6. Frame (standard) 251 132 92 450 360
7. Frame (standard) 251 132 92 310 210
8. Frame (standard) 251 132 92 310 210
9. Frame (standard) 251 132 92 310 210
10. Chiller 100 80 64 90 50
11. Noice reduction box 114 104 86 78 69
12. Air Compressor 120 80 92 87 67
13. Vacuum Cleaner 136 73 150 124 104
Imperial
Crates Length, L
(in)
Width, W (in) Height, H
(in)
Weight (lbs) Net weight
(lbs)
1. Table (standard) 98,8 80,7 14,2 825,0 600,6
2. Table Mid (standard) 98,8 67,7 14,2 726,0 539,0
3. Table Mid (standard) 98,8 67,7 14,2 726,0 539,0
4. Table (standard) 98,8 80,7 14,2 825,0 600,6

5
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Crates Length, L
(in)
Width, W (in) Height, H
(in)
Weight (lbs) Net weight
(lbs)
5. Traverse (standard) 132,7 20,5 39,4 440,0 290,4
6. Frame (standard) 98,8 52,0 36,2 990,0 792,0
7. Frame (standard) 98,8 52,0 36,2 682,0 462,0
8. Frame (standard) 98,8 52,0 36,2 682,0 462,0
9. Frame (standard) 98,8 52,0 36,2 682,0 462,0
10. Chiller 39,4 31,5 25,2 198,0 110,0
11. Noice reduction box 44,9 40,9 33,9 171,6 151,8
12. Air Compressor 47,2 31,5 36,2 191,4 147,4
13. Vacuum Cleaner 53,5 28,7 59,1 272,8 228,8

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6. Room Preparation
6.1 About Room Preparation
The accuracy obtained from the system depends upon room standards.
In order to maintain the high accuracy, the instructions given here must be adhered to.
The accuracy of the system is related to a temperature of +20° C / +68° F, and a relative humidity
of 50%.
However, the system can operate satisfactorily in temperatures between +10° C and +30° C / +50°
F and +86° F, and relative humidity of 30% to 80%.
6.2 Floor Covering
Floor-covering materials must be non-static.Do not use Nylon carpets.
Curtains should be non-static and lint-free.
6.3 Furniture
The furniture in the room (i.e. chairs, desks, cabinet’s etc.), additional to the system equipment,
should be made of low-shedding, low static-generating materials.
6.4 Material Storage
The conditions under which materials are stored is important where accuracy is concerned.
Assuming that an air-conditioned room is provided for the Cutting System, we recommend that the
material to be used is stored in a room with the same conditions as in the cutting room.
6.5 Workflow
Please note the recommended material transport direction indicated in the System Layout chapter.
To obtain maximum productivity, it is important to plan material handling.

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Note:
• Handling Heavy Materials is a danger to personal health.
• Actions should be taken to avoid manual lifting of Heavy Materials.
6.6 Floor Load and Level
The floor must be level and capable of supporting an evenly distributed load of 500 kg/m² (0.7 lbs/in²).
The flatness of the floor area prepared for the machine should be within +/- 5 mm (+/- 0.2 in.).
The floor must be able to prevent the table from being subjected to vibrations.(Most shop/office
floors meet these requirements.)
6.7 Computer Floor
Provided there are solid bases for table legs
(e.g. concrete foundation or steel beams), it is
recommended that the floor is built in the style
used for computer and electronic equipment
installations.
This style provides removable false-floor
sections with channels underneath for cables.
Illustration: concrete foundation, d is minimum
300 mm / 12 in.
6.8 Headroom
The total height of a standard machine is specified in the Tables Specification chapter.
If the machine is equipped with MultiCUT/MultiCUT-HP), a gallows is mounted on the X1 side of the
traverse:

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Ensure the headroom (Hg) is sufficient allowing the gallows to move freely:
mm Inch
XN2x 2300 90
XN4x 2300 90
6.9 Noise Level
The system generates a noise that can be hazardous if people have to work nearby the machine
over time.
Note:
• The noise level should be taken into account when the room and machine location is planned.
• For the operators, Hearing Protection should be available and used.