Esko Kongsberg X Series User manual

Kongsberg X-series
User Manual
09 - 2020 | X-series

Kongsberg X-series
Contents
1. Preface............................................................................................................................................................9
2. Change Record............................................................................................................................................. 10
3. Introduction.................................................................................................................................................. 12
3.1. Welcome.............................................................................................................................................. 12
3.2. FCC conformity statement.................................................................................................................. 13
4. Using this manual.........................................................................................................................................14
4.1. Main Sections...................................................................................................................................... 14
4.2. Name Styles and Symbols................................................................................................................... 15
4.3. Pictures and Illustrations.................................................................................................................... 15
4.4. Local Languages................................................................................................................................. 16
5. Safety Regulations....................................................................................................................................... 17
5.1. Introduction..........................................................................................................................................17
5.2. Responsibilities................................................................................................................................... 17
5.2.1. The manufacturer...................................................................................................................... 17
5.2.2. The owner................................................................................................................................. 17
5.2.3. The operators............................................................................................................................18
5.3. Requirements to be met by operators.................................................................................................18
5.4. Definition of use..................................................................................................................................19
5.5. Warning sign explanation.................................................................................................................... 19
5.6. Attention areas...................................................................................................................................22
5.6.1. Mains power disconnection.......................................................................................................22
5.6.2. High voltage, laser radiation and moving parts.........................................................................23
5.6.3. Loose clothing..........................................................................................................................23
5.6.4. Noise level................................................................................................................................ 23
5.6.5. Ejection of parts when milling..................................................................................................24
5.6.6. Milling stop time....................................................................................................................... 24
5.6.7. i-Camera strobing light.............................................................................................................24
5.7. Safety devices.....................................................................................................................................25
5.7.1. Overview....................................................................................................................................25
5.7.2. Emergency stop button............................................................................................................ 25
5.7.3. Yellow/black tape......................................................................................................................26
5.7.4. Warning lamps on Y carriage.................................................................................................... 26
5.7.5. DynaGuard Safety System......................................................................................................... 26
5.7.6. Milling warning lamp..................................................................................................................27
5.8. Protective equipment......................................................................................................................... 27
5.9. Procedures in case of Malfunctions....................................................................................................28
5.10. Check before operation.....................................................................................................................28
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Contents
5.11. Residual risks.....................................................................................................................................29
6. System Description..................................................................................................................................... 32
6.1. Naming conventions............................................................................................................................32
6.2. Main Power Switch..............................................................................................................................33
6.3. Operators Panel.................................................................................................................................. 33
6.4. Variable Blow Back............................................................................................................................. 35
6.5. Pressurized Air system....................................................................................................................... 36
6.6. Application programs available...........................................................................................................37
7. Basic Operations.......................................................................................................................................... 38
7.1. Power On Sequence.............................................................................................................................38
7.2. Reset Safety System........................................................................................................................... 39
7.3. Power Off Sequence............................................................................................................................39
7.4. Continue after Safety Break............................................................................................................... 40
8. Prepare for a Job......................................................................................................................................... 41
8.1. Introduction......................................................................................................................................... 41
8.2. Create Job.......................................................................................................................................... 41
8.3. Layer Setup......................................................................................................................................... 41
8.4. Production Setup................................................................................................................................42
8.5. Speed Setting..................................................................................................................................... 42
8.6. Flute/Grain Direction.......................................................................................................................... 42
8.7. Vacuum Zone Selection...................................................................................................................... 42
8.8. Job Execution.....................................................................................................................................43
8.9. Milling Production............................................................................................................................... 43
8.10. Make a Pen Plot.................................................................................................................................44
8.11. Work with X-Pad................................................................................................................................ 44
9. How To Procedures, Advanced................................................................................................................... 48
9.1. Cutting Thick Materials....................................................................................................................... 48
9.2. Hard Board Production....................................................................................................................... 48
9.3. Multi Pass Milling................................................................................................................................ 49
9.4. Job including Reverse Operation........................................................................................................49
9.4.1. Reverse Operation by Left and Right Rulers............................................................................. 50
9.4.2. Reverse Operation by use of Camera........................................................................................ 51
9.4.3. Reverse Operation in combination with Step and Repeat.........................................................52
9.5. Work with different Reference Point Settings.................................................................................... 52
9.6. MultiZone Production..........................................................................................................................53
9.6.1. MultiZone, Workflow..................................................................................................................54
10. System Setup............................................................................................................................................. 56
10.1. Introduction....................................................................................................................................... 56
10.2. Adjust X1 to X2 Angle........................................................................................................................ 57
10.3. Register Table Size............................................................................................................................57
10.4. Set Ruler Position............................................................................................................................. 58
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Kongsberg X-series
10.5. Set Main Reference Point.................................................................................................................. 58
10.6. Map Table Top Surface......................................................................................................................58
10.7. Reference Points and Coordinate System..........................................................................................59
10.8. Table Speed....................................................................................................................................... 61
10.9. Table Acceleration............................................................................................................................. 61
10.10. Jog Settings..................................................................................................................................... 61
10.11. Set Table Top Reference.................................................................................................................. 62
10.12. Milling Unit Setup.............................................................................................................................63
10.13. Board Size........................................................................................................................................ 63
11. Tool Configuration and Adjustment........................................................................................................... 64
11.1. Introduction........................................................................................................................................ 64
11.2. Adjust Active Tool.............................................................................................................................. 64
11.3. Tool Height Calibration.......................................................................................................................65
11.4. Lag Settings (for Rotating Tools)........................................................................................................65
11.5. Rotation Adjustment (for Rotating tools)............................................................................................67
11.6. Center Offset Adjustment.................................................................................................................. 68
11.7. Manual adjustment of Center Offset and angle...................................................................................69
11.8. Tool Offset..........................................................................................................................................69
11.9. Maintain Tool List (More...)................................................................................................................. 70
12. Tooling System........................................................................................................................................... 72
12.1. Tool handling and care....................................................................................................................... 72
12.2. Tool Inserts with built-in motor......................................................................................................... 72
12.3. Tool Heads available, overview.......................................................................................................... 73
12.4. Tool Head mount / dismount............................................................................................................. 74
12.5. FlexiHead...........................................................................................................................................74
12.6. PowerHead.........................................................................................................................................76
12.6.1. ø150 mm Crease Wheel............................................................................................................ 77
12.6.2. Crease Adapter ø26 mm..........................................................................................................78
12.6.3. Perforation Wheel ø60 mm......................................................................................................78
12.6.4. HD Knife Tool.......................................................................................................................... 80
12.6.5. V-notch Knife........................................................................................................................... 81
12.6.6. Bevel Knife 45..........................................................................................................................87
12.7. FoamHead..........................................................................................................................................87
12.8. MultiCUT/MultiCUT-HP...................................................................................................................... 90
12.8.1. Introduction............................................................................................................................. 90
12.8.2. Tool Head description............................................................................................................. 92
12.8.3. Cooling Water Connections..................................................................................................... 95
12.8.4. Safety issues...........................................................................................................................95
12.8.5. Precautions............................................................................................................................. 98
12.8.6. Milling advice..........................................................................................................................101
12.8.7. Cleaner Device....................................................................................................................... 104
12.8.8. Bits and Bit Change............................................................................................................... 104
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Contents
12.8.9. Chuck Change and Cleaning...................................................................................................107
12.8.10. Bit Slipping, Chuck Change....................................................................................................111
12.8.11. Bit Length and Position..........................................................................................................111
12.8.12. False Air valve....................................................................................................................... 112
12.8.13. Tool Adjustment.................................................................................................................... 112
12.8.14. Table Top and Height Adjustment......................................................................................... 113
12.8.15. Miscellaneous........................................................................................................................114
12.8.16. LubriCool (MultiCUT-HP only)................................................................................................ 114
12.9. Chiller no 1 (blue top) for MultiCUT-HP.............................................................................................. 119
12.9.1. Introduction............................................................................................................................ 119
12.9.2. Chiller, Error Conditions........................................................................................................ 120
12.9.3. Chiller Heater, Operation....................................................................................................... 120
12.10. Chiller 2016 / Chiller 2020 for MultiCUT-HP.....................................................................................122
12.10.1. Introduction.......................................................................................................................... 122
12.10.2. Startup................................................................................................................................. 123
12.10.3. Error Conditions................................................................................................................... 123
12.11. Measuring Foot................................................................................................................................124
12.12. Laser Pointer.................................................................................................................................. 125
12.13. X-Pad.............................................................................................................................................. 126
12.13.1. X-Pad Calibration.................................................................................................................. 126
12.13.2. Tool Depth and X-Pad........................................................................................................... 127
12.13.3. Limitations............................................................................................................................127
13. Tool inserts................................................................................................................................................128
13.1. Ball Point Pen....................................................................................................................................128
13.2. Bevel Knife....................................................................................................................................... 129
13.3. Bevel Knife U20................................................................................................................................130
13.4. Braille Tool....................................................................................................................................... 130
13.5. CorruSpeed Knife............................................................................................................................. 135
13.5.1. Tool adjustment...................................................................................................................... 137
13.6. Crease Tool...................................................................................................................................... 138
13.6.1. Tool adjustment...................................................................................................................... 138
13.7. Crease Tool, 60 mm..........................................................................................................................139
13.7.1. Tool adjustment...................................................................................................................... 139
13.8. Drill tools..........................................................................................................................................140
13.8.1. Flexi Drill Tool.........................................................................................................................140
13.8.2. Reboard Drill Tool................................................................................................................... 141
13.8.3. Drill Bit dimensions................................................................................................................ 141
13.8.4. Tool Adjustment.....................................................................................................................142
13.8.5. Drill Tool in ArtiosCAD............................................................................................................142
13.9. Foam Knife....................................................................................................................................... 142
13.10. Ink Tool........................................................................................................................................... 143
13.10.1. Liquid Ink Tool.......................................................................................................................143
13.10.2. Fibertip Tool......................................................................................................................... 144
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Kongsberg X-series
13.10.3. Tool adjustment....................................................................................................................144
13.11. KissCut............................................................................................................................................ 145
13.12. MicroCut..........................................................................................................................................147
13.13. Psaligraphy Knife............................................................................................................................ 149
13.13.1. Tool adjustment.................................................................................................................... 149
13.14. RBI 90-16 (Rigid Board Insert)......................................................................................................... 150
13.15. Reciprocating Knife......................................................................................................................... 151
13.15.1. Tool adjustment.....................................................................................................................152
13.16. Rigid Material Knife......................................................................................................................... 153
13.17. RotaCut........................................................................................................................................... 154
13.18. Static Knife..................................................................................................................................... 157
13.18.1. Tool adjustment.....................................................................................................................158
13.19. VI30-16 Knife Tool........................................................................................................................... 159
13.19.1. VIxx Knife Tool, Mounting/Adjustment...................................................................................159
13.20. VI45 Knife Tool................................................................................................................................161
13.20.1. VIxx Knife Tool, Mounting/Adjustment.................................................................................. 161
13.21. VI45-10/12 Knife Tool.......................................................................................................................162
13.21.1. VIxx Knife Tool, Mounting/Adjustment...................................................................................163
14. Maintenance.............................................................................................................................................. 165
14.1. Daily maintenance.............................................................................................................................165
14.2. Weekly maintenance........................................................................................................................ 165
14.3. Maintenance, external equipment.................................................................................................... 165
14.4. Maintenance, i-BF board feeder.......................................................................................................166
14.4.1. About maintenance................................................................................................................ 166
14.5. Maintenance, Take Up Unit.............................................................................................................. 166
14.5.1. General................................................................................................................................... 166
14.5.2. Spare Parts............................................................................................................................ 167
14.6. Maintenance, Motorized Roll Feeder.................................................................................................167
14.6.1. General....................................................................................................................................167
14.6.2. Spare Parts............................................................................................................................ 168
15. Fuse Replacement.....................................................................................................................................170
15.1. MPU fuses......................................................................................................................................... 170
15.2. X1 fuses.............................................................................................................................................171
15.3. X2 fuses........................................................................................................................................... 172
15.4. Y/Z fuses.......................................................................................................................................... 173
15.5. Tool Rotation/Reciprocating knife fuses.......................................................................................... 175
15.6. Chiller fuse, Hyfra (blue top)............................................................................................................. 175
15.7. Heater for Chiller Fuse......................................................................................................................176
15.8. Chiller 2016 / Chiller 2020 Fuse replacement....................................................................................177
15.9. Sound Insulating Box, Circuit Breaker for fan................................................................................... 177
15.10. TakeUp Unit, Fuse replacement......................................................................................................178
15.11. Motorized Roll Feeder, Fuse replacement........................................................................................179
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Contents
16. Roll Feeder................................................................................................................................................. 181
17. Collector Basket........................................................................................................................................ 182
18. TakeUp Unit............................................................................................................................................... 183
18.1. Introduction...................................................................................................................................... 183
18.2. Machine Description........................................................................................................................ 184
18.3. Safety............................................................................................................................................... 185
18.4. Features and components................................................................................................................187
18.5. General operation.............................................................................................................................188
18.6. Applying Winding Material................................................................................................................ 189
18.7. Start the TakeUp Unit...................................................................................................................... 190
18.8. Using the Autogrip Shaft.................................................................................................................. 191
19. Motorized roll feeder.................................................................................................................................194
19.1. Introduction...................................................................................................................................... 194
19.2. Safety regulations............................................................................................................................ 195
19.3. Safety devices.................................................................................................................................. 197
19.4. Safety precautions........................................................................................................................... 198
19.5. General operation.............................................................................................................................198
19.6. Loading material to the Motorized Roll Feeder................................................................................200
19.6.1. Release the Autogrip Shaft....................................................................................................200
19.6.2. Load material to the Autogrip Shaft...................................................................................... 201
19.6.3. Feeding the material through the MRF onto the table............................................................201
19.6.4. End of production................................................................................................................. 204
19.6.5. Intelligent vacuum.................................................................................................................204
19.7. Safety.............................................................................................................................................. 204
19.8. Jobs longer than table.................................................................................................................... 205
19.9. Understanding Print compensation for Soft signage.......................................................................205
20. i-BF Board Feeder....................................................................................................................................206
20.1. Introduction.....................................................................................................................................206
20.2. Health and Safety........................................................................................................................... 207
20.3. i-BF Specific Warnings - residual risks...........................................................................................209
20.4. Rules for Safe Operation.................................................................................................................. 211
20.5. Overview of Safety System..............................................................................................................213
20.6. i-BF Overview.................................................................................................................................. 215
20.7. Power On/Off Controls.....................................................................................................................218
20.8. Operator Controls............................................................................................................................219
20.9. Feeder Sequence of Operation........................................................................................................221
20.10. Touch Screen Display for Feeder Operation.................................................................................. 223
20.11. Starting Up the i-BF for Daily Operation........................................................................................ 225
20.12. Machine Faults, Errors and Remedies........................................................................................... 227
20.13. Suction Cups for Board Feeder..................................................................................................... 230
20.14. Emergency Stop Solution i-BF.......................................................................................................231
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Kongsberg X-series
21. Vacuum Cleaner........................................................................................................................................233
21.1. Vacuum Cleaner, Zefiro.................................................................................................................... 233
21.1.1. How to use..............................................................................................................................233
21.2. Vacuum Cleaner, High-capacity, TB ESKO....................................................................................... 235
21.2.1. How to use.............................................................................................................................235
21.3. Compact Vacuum Cleaner............................................................................................................... 238
21.3.1. How to use............................................................................................................................. 238
22. Install Software.......................................................................................................................................240
23. Frequently Asked Questions....................................................................................................................241
23.1. Machine............................................................................................................................................241
23.2. Tools................................................................................................................................................241
23.3. iPC.................................................................................................................................................. 243
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1
Kongsberg X-series
1. Preface
User Manual
for
Kongsberg X-series
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: 32597551
Esko-Graphics Kongsberg AS
www.esko.com
P.O.Box 1016, NO-3601 Kongsberg, NORWAY
Tel.: [phone]
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2Kongsberg X-series
2. Change Record
Date
dd-mm-yy
By Description
20-05-2016 jhbe Document is updated according to iPC ver 2.0
06-09-2016 jhbe The importance of MultiCUT chuck cleaning is
emphasized
07-10-2016 jhbe Information about LubriCool added
18-10-2016 jhbe CorruSpeed information updated
24-10-2016 jhbe MultiCUT-HP, new chiller and information about
old chiller added
12-11-2016 jhbe iBF Board Feeder information added
15-11-2016 jhbe MultiZone Production, recommended workflow
emphasized.
18-11-2016 jhbe V-notch description improved.
28-11-2016 jhbe Measuring foot, soft springs introduced.
29-11-2016 jhbe Psaligraphy knife tool information added
14-12-2016 jhbe MultiCUT-HP chapters updated
03-02-2017 jhbe TakeUp Unit, information added
15-02-2017 jhbe MultiCUT Sleeve Adjustment Tool, information
added
28-02-2017 jhbe i-BF Board Feeder, information updated
20-04-2017 jhbe Bevel 45 tool adapter description added
07-08-2017 jhbe The importance of Braille tool height adjustment
has been emphasized.
28-08-2017 jhbe The use of LubriCool Nozzle Unit and Suction
Ring, description added.
30-08-2017 jhbe VI30-16 Knife Tool, description added.
VI45-10/12 Knife Tool, description added.
06-11-2017 jhbe Droplets from cooling water connections,
description added
28-11-2017 jhbe List of tools that can be used for X-Pad calibration
has been updated
01-12-2017 jhbe Motorized Roll Feeder, information added
13.09.2018 DHO Reverse operation by use of camera added.
26.08.2019 DHO Motorized Roll Feeder section updated.
10