Esko Kongsberg XP User Manual
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10 - 2020 | XP
Kongsberg XP
User Manual
Kongsberg XP ii
Contents
1. Preface ............................................................................................................................................................
8
2. Change Record ...............................................................................................................................................
9
3. Introduction ...................................................................................................................................................
11
3.1. Welcome ...............................................................................................................................................
11
3.2. FCC conformity statement ...................................................................................................................
11
4. Using this manual .........................................................................................................................................
12
4.1. Main Sections ......................................................................................................................................
12
4.2. Name Styles and Symbols ...................................................................................................................
13
4.3. Pictures and Illustrations ....................................................................................................................
13
4.4. Local Languages .................................................................................................................................
14
5. Safety Regulations .......................................................................................................................................
15
5.1. Introduction .........................................................................................................................................
15
5.2. Responsibilities ...................................................................................................................................
15
5.2.1. The manufacturer ......................................................................................................................
15
5.2.2. The owner .................................................................................................................................
15
5.2.3. The operators ............................................................................................................................
16
5.3. Requirements to be met by operators .................................................................................................
16
5.4. Definition of use ..................................................................................................................................
17
5.5. Warning sign explanation ....................................................................................................................
17
5.6. Attention areas ...................................................................................................................................
20
5.6.1. Mains power disconnection .......................................................................................................
20
5.6.2. High voltage, laser radiation and moving parts ........................................................................
20
5.6.3. Loose clothing ..........................................................................................................................
21
5.6.4. Noise level .................................................................................................................................
21
5.6.5. Ejection of parts when milling ..................................................................................................
21
5.6.6. Milling stop time ........................................................................................................................
21
5.6.7. i-Camera strobing light .............................................................................................................
22
5.7. Safety devices .....................................................................................................................................
23
5.7.1. Overview ....................................................................................................................................
23
5.7.2. Emergency stop button ............................................................................................................
23
5.7.3. Yellow/black tape ......................................................................................................................
24
5.7.4. Warning lamps on Y carriage ....................................................................................................
24
5.7.5. DynaGuard safety system ..........................................................................................................
25
5.7.6. Milling warning lamp .................................................................................................................
26
5.8. Protective equipment .........................................................................................................................
26
5.9. Procedures in case of Malfunctions ....................................................................................................
27
5.10. Check before operation .....................................................................................................................
27
Contents
5.11. Residual risks .....................................................................................................................................
27
6. System Description .....................................................................................................................................
30
6.1. Naming Conventions ...........................................................................................................................
30
6.2. Main Power Switch ..............................................................................................................................
31
6.3. Operators Panel ...................................................................................................................................
31
6.4. High Pressure Air System ...................................................................................................................
33
6.5. Application Programs Available ..........................................................................................................
34
7. Basic Operations ..........................................................................................................................................
35
7.1. Introduction .........................................................................................................................................
35
7.2. Power On Sequence ............................................................................................................................
35
7.3. Reset Safety System ...........................................................................................................................
36
7.4. Power Off Sequence ...........................................................................................................................
36
7.5. Continue after Safety Break ................................................................................................................
37
8. Prepare for a Job .........................................................................................................................................
38
8.1. Introduction .........................................................................................................................................
38
8.2. Create Job ..........................................................................................................................................
38
8.3. Layer Setup .........................................................................................................................................
38
8.4. Production Setup ................................................................................................................................
39
8.5. Speed Setting .....................................................................................................................................
39
8.6. Flute/Grain Direction ..........................................................................................................................
39
8.7. Vacuum Zone Selection ......................................................................................................................
39
8.8. Job Execution ....................................................................................................................................
40
8.9. Corrugated Production .......................................................................................................................
40
8.10. Milling Production ..............................................................................................................................
41
8.11. Make a Pen Plot ..................................................................................................................................
41
9. How To Procedures, Advanced ...................................................................................................................
42
9.1. Optimize vacuum effect ......................................................................................................................
42
9.2. Cutting Thick Materials .......................................................................................................................
43
9.3. Hard Board Production .......................................................................................................................
43
9.4. Multi-pass ...........................................................................................................................................
44
9.5. Job including Reverse Operation ........................................................................................................
44
9.5.1. Reverse Operation by Left and Right Rulers ..............................................................................
46
9.5.2. Reverse Operation by use of Camera .......................................................................................
46
9.5.3. Reverse Operation in combination with Step and Repeat .........................................................
47
9.6. Work with different Reference Point Settings ....................................................................................
48
9.7. MultiZone Production ..........................................................................................................................
48
9.7.1. MultiZone, Workflow ..................................................................................................................
50
10. System Setup .............................................................................................................................................
52
10.1. Introduction .......................................................................................................................................
52
10.2. Adjust X1 to X2 Angle ........................................................................................................................
53
10.3. Register Table Size ............................................................................................................................
53 iii
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Kongsberg XP
10.4. Adjust Measuring Station Position ....................................................................................................
54
10.5. Set Ruler Position .............................................................................................................................
54
10.6. Set Main Reference Point ..................................................................................................................
54
10.7. Map Table Top Surface ......................................................................................................................
55
10.8. Calibrate Foot on Measuring Station .................................................................................................
56
10.9. Reference Points and Coordinate System .........................................................................................
56
10.10. Table Speed .....................................................................................................................................
58
10.11. Table Acceleration ............................................................................................................................
59
10.12. Jog Settings .....................................................................................................................................
59
10.13. Set Table Top Reference ..................................................................................................................
60
10.14. Vacuum Setup ..................................................................................................................................
60
10.14.1. Vacuum Zone Configuration ...................................................................................................
60
10.15. Milling Unit Setup .............................................................................................................................
62
10.16. Conveyor Belt Control ......................................................................................................................
62
10.16.1. Split Sheet Feed .....................................................................................................................
62
10.16.2. Sheet Feed Correction ...........................................................................................................
63
10.17. Board Size ........................................................................................................................................
63
11. Tool Configuration and Adjustment ...........................................................................................................
64
11.1. Tool Configuration ..............................................................................................................................
64
11.2. Tool Names ........................................................................................................................................
66
11.3. Adjust Active Tool ..............................................................................................................................
67
11.4. Lag Settings (for Rotating Tools) ........................................................................................................
67
11.5. Tool Height Calibration .......................................................................................................................
68
11.6. Rotation Adjustment (for Rotating tools) ............................................................................................
69
11.7. Center Offset Adjustment ...................................................................................................................
70
11.8. Tool Offset ..........................................................................................................................................
71
11.9. Knife angle calibration ........................................................................................................................
71
11.10. Maintain Tool List .............................................................................................................................
72
12. Tooling System ...........................................................................................................................................
74
12.1. Introduction .......................................................................................................................................
74
12.2. Tool Handling and Care ......................................................................................................................
74
12.3. How to Replace a Tool .......................................................................................................................
75
12.4. Two or more tools of the same type ..................................................................................................
75
12.5. Measuring Station ..............................................................................................................................
76
12.6. HDU - Heavy Duty Unit .......................................................................................................................
78
12.6.1. Crease Wheel ø150 mm ............................................................................................................
78
12.6.2. V-notch Knife Tool ...................................................................................................................
80
12.6.3. HD Knife Tool ...........................................................................................................................
85
12.6.4. Crease Adapter .......................................................................................................................
88
12.6.5. Perforation Wheel ø60 mm .....................................................................................................
88
12.6.6. Bevel Knife 45 .........................................................................................................................
90
12.7. Foam Knife .........................................................................................................................................
92
Contents
12.8. Dual HDU - Dual Heavy Duty Unit .......................................................................................................
94
12.8.1. Dual HDU HD Perf Position .......................................................................................................
96
12.8.2. New mounting procedure for HD insert tools ..........................................................................
98
12.9. VariAngle unit ...................................................................................................................................
100
12.9.1. Introduction ............................................................................................................................
100
12.9.2. Safety precautions ................................................................................................................
100
12.9.3. Tool description ......................................................................................................................
101
12.9.4. Description of knife blade adapters .......................................................................................
102
12.9.5. Tool adjustment .....................................................................................................................
104
12.9.6. Basic modes of operation ......................................................................................................
105
12.9.7. Workflows, set-up and optimization .......................................................................................
107
12.9.8. Advanced operations .............................................................................................................
108
12.9.9. Work area limitations ..............................................................................................................
111
12.9.10. Material lift ............................................................................................................................
112
12.10. HPMU - High Power Milling Unit .......................................................................................................
112
12.10.1. Introduction ...........................................................................................................................
112
12.10.2. Tool Head description ...........................................................................................................
113
12.10.3. Safety issues .........................................................................................................................
115
12.10.4. Precautions ...........................................................................................................................
117
12.10.5. Milling advice .........................................................................................................................
121
12.10.6. Cleaner Device ......................................................................................................................
124
12.10.7. Bits and Bit Change ..............................................................................................................
124
12.10.8. Chuck Change and Cleaning .................................................................................................
126
12.10.9. Bit Slipping, Chuck Change ..................................................................................................
130
12.10.10. Bit Length and Position ......................................................................................................
130
12.10.11. Tool Adjustment ...................................................................................................................
131
12.10.12. Table Top and Tool Height Adjustment ................................................................................
131
12.10.13. Miscellaneous ......................................................................................................................
132
12.10.14. LubriCool (MultiCUT-HP only) ..............................................................................................
133
12.11. Chiller no 1 (blue top) for HPMU .......................................................................................................
136
12.11.1. Introduction ...........................................................................................................................
136
12.11.2. Chiller Heater, Operation .......................................................................................................
137
12.11.3. Chiller, Error Conditions ........................................................................................................
139
12.12. Chiller 2016 / Chiller 2020 for HPMU ................................................................................................
139
12.12.1. Introduction ...........................................................................................................................
139
12.12.2. Startup .................................................................................................................................
140
12.12.3. Error Conditions ....................................................................................................................
141
12.13. VibraCut ..........................................................................................................................................
142
12.14. Rigid Material Knife (RM Knife Tool) ................................................................................................
144
12.15. HiForce Knife ..................................................................................................................................
145
12.16. Psaligraphy Knife ............................................................................................................................
148
12.17. PressCut ..........................................................................................................................................
149
12.18. RotaCut ...........................................................................................................................................
152 v
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Kongsberg XP
12.19. Braille Tool ......................................................................................................................................
155
12.20. CorruSpeed Knife ...........................................................................................................................
159
12.20.1. Tool adjustment ....................................................................................................................
161
12.21. Braille Tool .......................................................................................................................................
161
12.22. Drill / Pen Tool ................................................................................................................................
166
12.23. Drill Tool .........................................................................................................................................
168
12.24. Ballpoint Pen ..................................................................................................................................
169
12.25. Measuring Foot ...............................................................................................................................
170
12.26. Laser Pointer ..................................................................................................................................
170
13. Maintenance ...............................................................................................................................................
171
13.1. General ...............................................................................................................................................
171
13.2. Daily Maintenance .............................................................................................................................
171
13.3. Weekly Maintenance .........................................................................................................................
171
13.4. Monthly Maintenance ........................................................................................................................
172
13.5. Maintenance, External Equipment ....................................................................................................
177
13.6. Maintenance, Take Up Unit ...............................................................................................................
177
13.6.1. General ....................................................................................................................................
177
13.6.2. Spare Parts ............................................................................................................................
178
14. Fuse Replacement .....................................................................................................................................
179
14.1. MPU fuses .........................................................................................................................................
179
14.2. X1 .....................................................................................................................................................
180
14.3. X2 ......................................................................................................................................................
181
14.4. Y .......................................................................................................................................................
183
14.5. P1/P2 fuses ......................................................................................................................................
184
14.6. Fuses on various tools .....................................................................................................................
186
14.7. Chiller fuse, Hyfra (blue top) .............................................................................................................
187
14.8. Heater for Chiller Fuse .....................................................................................................................
188
14.9. Chiller 2016 / Chiller 2020 Fuse replacement ...................................................................................
188
14.10. Sound Insulating Box, Circuit Breaker for fan .................................................................................
189
14.11. TakeUp Unit, Fuse replacement ......................................................................................................
190
14.12. Motorized Roll Feeder, Fuse replacement .......................................................................................
191
15. Roll Feeder .................................................................................................................................................
193
16. Collector Basket ........................................................................................................................................
194
17. TakeUp Unit ................................................................................................................................................
195
17.1. Introduction .......................................................................................................................................
195
17.2. Machine Description .........................................................................................................................
196
17.3. Safety ................................................................................................................................................
197
17.4. Features and components ................................................................................................................
199
17.5. General operation ............................................................................................................................
200
17.6. Applying Winding Material ................................................................................................................
201
17.7. Start the TakeUp Unit ......................................................................................................................
202
Contents
17.8. Using the Autogrip Shaft .................................................................................................................
203
18. MRF Quick start guide ..............................................................................................................................
206
19. MRF Weight list .........................................................................................................................................
207
20. Vacuum Cleaner .......................................................................................................................................
208
20.1. Vacuum Cleaner, Zefiro ...................................................................................................................
208
20.1.1. How to use .............................................................................................................................
208
20.2. Vacuum Cleaner, High-capacity, TB ESKO .......................................................................................
210
20.2.1. How to use ............................................................................................................................
210
20.3. Compact Vacuum Cleaner ...............................................................................................................
213
20.3.1. How to use .............................................................................................................................
213
21. Install Software .........................................................................................................................................
215
22. Frequently Asked Questions ....................................................................................................................
216
22.1. Machine ............................................................................................................................................
216
22.2. Tools ................................................................................................................................................
216
22.3. iPC ...................................................................................................................................................
217 vii
1
Kongsberg XP
1. Preface
User Manual for
Kongsberg XP 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: D3621
Part no: 32597502
Esko-Graphics Kongsberg AS www.esko.com
P.O.Box 1016, NO-3601 Kongsberg, NORWAY
Tel.: +47 32 28 99 00
8
Kongsberg XP
2
2. Change Record
By
30.11.2018
28.02.2019
10.04.2019
29.04.2019
04.07.2019
26.08.2019
20.09.2019
25.09.2019
20.02.2020
06.03.2020
Date dd-mm-yy
03-02-2017
18-04-2017
20-04-2017
20-04-2017
03-07-2017
07-08-2017
30-08-2017
06-11-2017
17-11-2017
01-12-2017
17.03.2018
11.05.2018
19.09.2018
DHO
DHO
DHO
DHO
DHO
DHO
DHO
DHO
DHO
DHO jhbe jhbe jhbe jhbe
DHO jhbe jhbe jhbe jhbe jhbe jhbe
DHO
DHO
Description
TakeUp Unit, information added
Measuring station operation, information added.
Braille tool description added
Bevel 45 tool adapter description added
Tool Insert Position, limitation information added.
The importance of Braille tool height adjustment has been emphasized.
Braille tool info added.
Droplets from cooling water connections, description added
Board Stacker, information added.
Motorized Roll Feeder, information added
Motorized Roll Feeder, information removed. Work area information added.
Operator panel upgrade June-September 2018 included + misc.
Section for Underside Camera added. Reverse operation by use of camera added.
2nd Fast Tool Enabler for Cx (and XP) and misc.
Safety precautions updated. Feeder / Stacker procedures updated.
2nd Fast Tool Enabler renamed to Fast Tool
Adapter. Caster wheels. Feeder suction arm.
Statement for Warp vs. Material Stacker updated.
Dual HDU added
Motorized Roll Feeder section updated.
MRF Quick start and Weight list added.
Monthly Maintenance updated.
Safety sections + misc. updated
Updated for Chiller 2020
9
2
Date dd-mm-yy
02.04.2020
08.06.20
14.09.2020
22.09.2020
27.10.2020
By
DHO
DHO
DHO
DHO
DHO
Description
Safety section updated
FCC conformity statement added
Minor update
Warning sign "Sharp knives" added
VariAngle unit included
Kongsberg XP
10
Kongsberg XP
3
3. Introduction
3.1. Welcome
Welcome to the User Manual for Kongsberg XP running iPC .
This manual will provide a complete and detailed description of all 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 2.2
.
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
11
4
4. Using this manual
4.1. Main Sections
The manual is divided into the following Main Sections :
• All safety related issues are discussed.
• This chapter provides basic knowledge about the machine.
• This chapter provides basic knowledge about how to operate the machine.
• A typical workflow is described, with detailed information about each step.
Optional functions for the advanced user:
• Cutting Thick Materials - advices.
• Hard Board Production - advices.
• Multi Pass Creasing or Milling - how to.
• Jobs including Reverse Operations - how to.
• Work with different Reference Point Settings - how to.
• MultiZone Production - how to.
Work with Registration Marks
• A step by step workflow.
• Settings specifying the general behaviour of the system.
Tool Configuration and Adjustment
• General information about the tooling and adjustment of tools.
12
Kongsberg XP
Kongsberg XP
4
• Tool descriptions.
• This chapter describes maintenance to be carried out by the customer.
Fuse Replacement
• Fuse location and specification.
Appendices
• Roll Feeder - basic information.
• Vacuum Cleaner - basic information.
4.2. Name Styles and Symbols
Name or style
Pop-up dialog
Start button
OK
Menu Bar -> Edit -> Options
Description
This is the dialog that appears when you click the Right mouse button.
The italic style indicates this is a button on the Operator
Panel .
The bold style indicates this is a button or function in the
GUI.
Link to topic.
Menu selection: From Menu Bar , select Edit and then
Options .
This symbol indicates that the function depends upon actual hardware.
If hardware is not available, this functions is hidden.
This symbol indicates that the function is license dependant.
4.3. Pictures and Illustrations
Orientation
In this document, pictures and illustrations related to the Cutting Table are viewed as shown here:
13
4
4.4. Local Languages
This manual is available in a wide range of local languages.
Screen pictures and illustrations remain in English language.
For safety related illustrations, text is translated.
Kongsberg XP
14
Kongsberg XP
5
5. Safety Regulations
5.1. Introduction
The XP table is designed to conform to Safety Regulation standards.
Dangers are designed away as far as practically possible. Nevertheless, all hazards could not be removed. This section must be read carefully to understand the remaining risks, warning symbols, responsibilities, requirements and safety precautions.
In particular, operating the table can involve hazards if:
• The operator does not follow the operating instructions.
• The table is used for non-intended purposes.
Special attention should be paid upon the following:
• Be careful when handling tools with knife blades. Knives are extremely sharp.
• Be careful when operating the milling tool . The milling spindle needs a few seconds to stop, and any contact with a rotating milling bit is very dangerous.
• Use appropriate techniques and tools when handling heavy materials.
• The machine has fast moving parts like the traverse and tool head . Stay away from the danger zone during operation.
• The system is equipped with a class II laser pointer. Do not stare directly into it. That can damage your eyes.
In addition to the safety regulation described below, there are safety warnings in the respective topics.
5.2. Responsibilities
5.2.1. The manufacturer
The manufacturer is responsible for delivering the system according to safety regulation standards.
5.2.2. The owner
The owner is responsible for:
• Ensuring that the system is used for its intended use only
• Ensuring that only authorized and trained personnel operate the system
15
5
Kongsberg XP
• Preventive maintenance as described in the maintenance section of the user manual
• That the local Regulations regarding installation and operation are fulfilled
• Ensure that safe work procedures and awareness of potential hazards are periodically reviewed and enforced
5.2.3. The operators
The operators are responsible for:
• Operating the system only when it is in a flawless state
• Operating the system according to operating instructions
• Ensuring that no unauthorized personnel come close to the system.
5.3. Requirements to be met by operators
Personnel operating the system must:
• Be adequately trained.
• Have read and understood the instructions described in safety regulation as well as any other safety warnings.
Training will be given to operator(s) nominated by the customer by the Esko service engineer as part of the system installation.
The training covers:
• Safety regulations
• Start-up and shut-down procedures
• Online help / user manuals
• Set-up procedures
• Adjustment procedures
• Workflow
• Maintenance
For additional training courses, contact Esko global support.
Un-trained personnel shall under no circumstances be allowed to operate the system!
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.
In particular, milling operations shall only be performed by properly trained operators due to the dangerous nature of the milling tool .
16
Kongsberg XP
5
5.4. Definition of use
The system is designed for use within applications, materials, tools and workflow as described in the user manual for iPC . In the user manual for cutting table , intended use is described in the following sections:
•
•
•
Any other use is considered as non-intended use. Examples of non-intended use:
• Operation by operators not meeting the requirements as described above.
• Unauthorized modifications (bridging safety devices, removing covers etc.)
• Deliberately avoiding the DynaGuard safety system by reaching under the lower beam to avoid detection.
• Utilizing accessories other than those specified by Esko.
• Operating or maintaining the machine or any of its accessories under the influence of drugs, alcohol or medication that could impair your judgment and vigilance.
Non-intended use may cause:
• Health hazards and injuries.
• Damage to the system.
• Incorrect functionality.
• Damage to work materials.
Note: Esko is not liable for any damage resulting from such non-intended use.
5.5. Warning sign explanation
High voltage warnings
• Main Power Unit (MPU) and vacuum pump
Do not open cover on either MPU or vacuum pump before mains is disconnected from cutting table and vacuum pump.
Note: Different instruction for Cxx and Xxx.
• IBAG inverter
Do not open cover on IBAG inverter before mains is disconnected from cutting table .
Note: Different instruction for Cxx and Xxx.
17
5
Kongsberg XP
• Chiller
Do not open cover on chiller before mains is disconnected from cutting table .
Note: Different instruction for Cxx and Xxx.
• Vacuum cleaner
Do not open cover on vacuum cleaner before mains is disconnected from cutting table .
Note: Different instruction for Cxx and Xxx.
Note: Equipment with high voltage may be opened by authorized personnel only.
Caution, laser
LASER RADIATION
DO NOT STARE INTO BEAM
DIODE LASER
MAX OUTPUT 1 mW
WAVELENGTH 650-660 nm
EN 60825-1: 1991+A11:1996
CLASS II LASER PRODUCT
AVOID EXPOSURE
Laser radiation emitted from this aperture
General warning
Milling tools
Milling tools require skill, and must be run by
QUALIFIED OPERATORS ONLY
This is based on
• Safety issues
• Protection of the equipment
• Taking care of expensive materials
Hand Squeeze
Potential areas with a risk of being squeezed are marked with the Hand Squeeze sign.
These areas are:
• Between X-axis end stopper and traverse wagon.
18
Kongsberg XP
5
Sharp knives
Potential risk of being cut by sharp knives.
Moving Parts
Potential areas with a risk of being hit by Moving Parts are marked with the
Moving Parts sign.
These areas are:
• Both traverse ends.
• Y carriage.
• Tool head(s).
Do not Touch
Potential areas with a risk of being squeezed are marked with the Do Not Touch sign.
These areas are:
• Between Y carriage and rack
• Between the table top and the moving traverse.
• Underneath the tool head.
Hearing Protection
The Hearing Protection symbol indicates areas where the use of hearing protection is compulsory.
Eye Protection
The Eye Protection symbol indicates areas where the use of eye protection is compulsory.
Do not leave the machine running if the vacuum cleaner can be over-filled. This might cause damage, or in worst case a fire if the suction house is clogged.
See also
on page 115 in the section for milling.
19
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Kongsberg XP
Knife blades and milling bits are extremely sharp.
This symbol is used in documentation to indicate operations where there is risk of being injured.
Additional warning signs are found in relevant sections.
5.6. Attention areas
5.6.1. Mains power disconnection
The main power switch on the operator station is intended for daily power on/off
To permanently disconnect mains power, e.g. for maintenance, use a lockable on/off switch at the power line if available, or remove the plug from the wall outlet. In addition, turn off the main power switch.
Note: A lockable on/off switch on the power line may be required by local regulations, but is part of the site preparation, site owner’s responsibility, not included in the Kongsberg system delivery unless agreed.
5.6.2. High voltage, laser radiation and moving parts
20
Kongsberg XP
5
5.6.3. Loose clothing
While working with this machine, do not wear clothes or jewelry that can entangle with moving parts of the machine:
• Ties
• Loose necklaces
• Scarfs
5.6.4. Noise level
Hearing protection should be used by any personnel exposed to the noise from the machine. This is particularly recommended during milling operation or when using reciprocating tools. The noise level heavily depends on the material that is processed.
5.6.5. Ejection of parts when milling
Eye protection must always be used to prevent injury from potential risk of breaking milling bits or pieces of processed material.
See also Safety issues on page 115 in the section for milling.
5.6.6. Milling stop time
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Kongsberg XP
The milling spindle does not stop instantly. Always ensure that the red lamp has stopped flashing, and by visual inspection that the milling bit has come to a complete standstill before touching it.
Note: Only specially trained operators are allowed to operate milling tools.
5.6.7. i-Camera strobing light
If your system includes i-Camera, please read this warning carefully:
WARNING
i-Camera is equipped with LED strobing light.
The LED default frequency (10 Hz) is in a range that can cause photosensitive epileptic reactions amongst susceptible people.
If a person is known to be susceptible, the frame rate, frequency of strobing, can be reduced to as low as 1 Hz from the camera configuration menu.
At that rate, seizures are not known to happen.
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5
5.7.
Safety devices
5.7.1. Overview
5.7.2. Emergency stop button
Emergency stop buttons.
OUT
IN
Switch positions
- Normal operation enabled
- Emergency stop active. Servo power to the machine is switched off
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Kongsberg XP
Note:
Activating the emergency stop button does not provide a guarantee against injury. Due to the high kinetic energy of moving parts, do not underestimate stopping distances of traverse , Y carriage and tool head .
To Continue operation after emergency stop, proceed as follows
1.
Ensure the table is free from obstructions and ready for operation.
2.
Pull out the emergency stop button.
3.
Reset the safety system by pressing the Pause / Servo on pushbutton.
4.
Observe that servo power is switched on.
5.
Press Start to continue.
5.7.3. Yellow/black tape
The yellow/black tape indicates the attention area.
This area is restricted to operators and other trained personnel.
5.7.4. Warning lamps on Y carriage
Light is
Off
On
Flashing
Light is
Off
On
Flashing
Description, Y carriage
Servo power is off
Servo power is on, DynaGuard safety system is enabled, table is ready for operation
DynaGuard safety system is activated.
Reset safety system to continue operation
Description, milling unit
Milling spindle not running
Milling spindle running
Milling spindle running (starting or stopping)
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5.7.5. DynaGuard safety system
The lower beam is at about 70 mm / 2.75 in. above the table top to allow materials of 50 mm / 2 in.
thickness. It is possible, but very dangerous to reach under the beam and into the hazard zone.
The cutting table is not designed nor intended to be used like that.
The DynaGuard safety system consists of:
• Two light beams in front of the traverse and two behind.
• One light beam on traverse front to prevent squeeze risk.
• A deflective stop mechanism mounted on each end of the traverse .
Machine movement will stop and servo power will be switched off if:
• One of the light beams is broken.
• The stop mechanism is activated.
Continue operation
To continue operation after the DynaGuard safety system system has been activated, do:
1.
Ensure the table is free from obstructions and ready for operation.
2.
Ensure the traverse safety stop switches are centered, see illustration below.
3.
Reset the DynaGuard safety system by pressing the Pause / Servo on pushbutton.
4.
Observe that servo power is switched on.
5.
Press Start to continue.
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Kongsberg XP
5.7.6. Milling warning lamp
The milling warning lamp indicates that the milling bit is rotating.
Constantly lit indicates running.
Flashing indicates starting or stopping.
Before touching the milling bit , always ensure also by visual inspection that the bit has come to a complete standstill.
5.8. Protective equipment
For the operators, Esko recommends the following protective equipment:
Close-fitting clothes to avoid being caught by the beam or the tool head which can cause injuries.
Gloves to protect against cuts from materials with sharp edges.
Eye protection must be used by any personnel working with milling.
Always use hearing protection when working with the machine for a longer period of time.
The acoustic noise level will vary with the type of operation and tooling, but a typical average level is 78.5 – 83.5 dBA and a maximum level of 98.5 dBA.
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5.9. Procedures in case of Malfunctions
Trouble-shooting and repair shall be performed by authorized personnel only.
Contact the Esko global support.
5.10. Check before operation
Before operating the equipment, check the following:
• Electrical cables without damage
• Clean workspace
• Unobstructed motions
• Servo lamp functioning
• Milling spindle warning lamp functioning
• Electrical parts and connections without excessive moisture
• Tools properly fastened
• Vacuum cleaner not full
• Emergency buttons unobstructed
• Operator has proper training
5.11. Residual risks
Despite all safety protection means incorporated in this machine, there are some residual safety risks to be aware of:
Beneath traverse end
The lower part of the traverse end is un-protected.
Actions:
• Children are not supposed to be inside the machine safety attention area
• Do not work or stay beneath the traverse while the machine is operating.
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5
Y carriage
Rear side of traverse
Inside cable chain
Kongsberg XP
The top of the Y carriage is un-protected in all four directions.
Actions:
• Do not access the table work area or approach the traverse while the machine is operating.
DynaGuard safety system light beams will emergency-stop all machine motions as fast as possible when interrupted by a body part or other object. When the feeder bar or feeder paws
(illustration) are mounted, the distance between the rear beam and the mechanics is reduced
Actions:
• Stay out of this area while the machine is operating.
There is a risk for squeezing between the cable chain and the table frame.
Actions:
• Stay out of this area while the machine is operating.
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Under the lower DynaGuard light beam
Kongsberg XP
5
It is possible to reach under the lower DynaGuard light beam into tool hazard areas. Intentionally doing this during machine operation is very dangerous and considered non-intended use.
Touching the milling bit while rotating
Stop time of the milling spindle is up to 4 seconds.
This is sucient time to access and touch the milling bit before it has come to a complete stop.
It is crucial that the operator always ensures by visual inspection that the milling bit has come to a complete standstill before touching it.
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6
6. System Description
6.1.
Naming Conventions
Machine
1 Cutting Table
2 Tools
3 Y carriage
4 Traverse
Axes
5 Main Power on/off switch
6 Operator Panel
7 Emergency Stop button
8 Main Power Unit (MPU)
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X - X-axis
Y - Y-axis
X1 - X1 end of traverse
P1 - P1 Tool Position .
P2 - P2 Tool Position .
Kongsberg XP
X2 - X2 end of traverse
6.2.
Main Power Switch
The Main Power Switch is located on the Operator Station :
Switch positions
O - Main Power to the machine is switched OFF.
I - Main Power to the machine is switched ON.
6.3. Operators Panel
Kongsberg XP
6
Power On
Mains Power on/off indication.
Servo Power On
Servo Power on/off control.
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Start
Press this button to Start Operation .
Pause / Safety System Reset
Press this button to Pause Operation and Reset Safety System .
Vacuum On/Off
Press this button to switch Vacuum On/Off .
Provides material hold down.
Set Panel Reference Point
Press this button to set Panel Reference Point .
If Fixed Reference Point is disabled, the current position of Laser Pointer is set as the new Reference Point .
Move to Table Zero
Press this button, then the Start button, to move the tool head to Selected
Reference Point .
The Table Zero Mode is automatically selected at Power on .
The system remains in the Table Zero Mode until Table Zero movement is completed.
Jog buttons
Press the Jog buttons to move the tool head in the desired direction.
The system must be in Pause mode, i.e. the Pause button must be lit, for these buttons to be operative.
Note: It is possible to configure the jog direction, see Option -> System setup .
Incremental Jog
Press this button to select Incremental jog mode.
Press the button a second time to disable Incremental jog mode.
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6
Press the two arrows to move the tool head a large step.
Press the single arrow to move the tool head a small step.
The size of the incremental movement can be changed from Option-> System setup.
Tool Down
Press the Tool Down button to manually operate the machine with a tool in the down position.
Cancel by pressing Tool Down a second time.
Vacuum release mode
For details about this function, see separate chapter 'Vacuum control'.
If activated for more than 2 seconds, this button activates the Manual Belt
Clamp function.
6.4. High Pressure Air System
General
The High Pressure Air System supplies the valves and tooling with compressed air.
The compressed air input is connected to a combined Pressure Regulator Valve / Water Trap .
Wall Outlet - Wall Outlet
A - Air Tube
R - Pressure Regulator Valve
P - Pressure Gauge
W - Water Trap
T - Air Tube to Tools and Valves
For details regarding air supply requirements, see Site Preparation Manual .
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Air Pressure Regulator settings
Kongsberg XP
The air pressure should be adjusted to minimum 6 bar (6 kg/cm2, 6*105 Pa).
Recommended pressure level is 7 bar (7 kg/cm2,
7*105 Pa).
Consequences of too low air pressure level:
• Execution will stop.
• An error message is displayed.
6.5. Application Programs Available
After installation of iPC , the following application programs are available iPC
Control program for the Cutting Table .
For more information, see User Manual for i-cut Production Console .
SysLoad
Program for download of updates to CU–modules
HWT900XP
Hardware test program, see separate HWT900XP User Manual .
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7
7. Basic Operations
Keep away from Moving Parts during operation.
Do not lean on Racks , Guide Ways or Traverse during operation, as this may cause personal injury.
Before starting any operation, make sure that:
• The Table is free from obstructions
• No unauthorized personnel come close to the table
7.1. Introduction
All procedures for how to run the machine are based upon the following assumptions:
• The User Interface is up and running.
• The actual Tools are properly mounted and adjusted.
7.2. Power On Sequence
Ensure the table is free from obstructions and ready for operation.
Follow these steps to power up the system and get ready to work:
1
2
Front End PC
Switch on the PC and the monitor.
Table Power
Switch the table on using the Main Power Switch .
Note: After power off, wait minimum 5 sec. before the system is switched on again.
3 iPC
From Desktop, double-click the icon for iPC
Check that no error message indicates faulty conditions.
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6
7
4
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Kongsberg XP
Safety System
Reset the Safety System by pressing the Pause pushbutton.
Servo Power
Press the Servo On pushbutton.
The Warning Lamp on top of the Y carriage should be on without flashing.
Table Zero Sequence
Press Start pushbutton to complete the Table Zero Sequence .
The machine will move to the Selected Reference Point .
The table is now ready for operation.
7.3. Reset Safety System
Press Pause to Reset Safety System .
7.4. Power Off Sequence
Follow these steps to power down the system:
1 Servo Power
Press the Servo On pushbutton to switch Servo Off .
2
3
Table Power
Turn Table Power off using the Main Power Switch .
Note: After power off, wait minimum 5 sec. before the system is switched on again.
Front End PC
To switch off the PC, use the Operating System shutdown procedure..
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7.5. Continue after Safety Break
If the Safety System is activated, all movements on the table are stopped and the Warning Lamp starts flashing.
To continue operation, proceed as follows:
1 Ensure the table is free from obstructions and ready for operation.
2 Reset the Safety System by pressing the Pause pushbutton.
3
4
The Warning Lamp on top of the Y carriage should be constantly lit (not flashing).
Observe that Servo Power is switched on,
Press Start to continue.
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8. Prepare for a Job
8.1. Introduction
Keep away from Moving Parts during operation.
Do not lean on Racks , Guide Ways or Traverse during operation, as this may cause personal injury.
Before starting any operation, make sure that:
• The Table is free from obstructions
• No unauthorized personnel come close to the table
The Starting Point in this procedure is to Create a Job from a file already available in My Jobs List .
Detailed information about the complete iPC workflow is available in the following manuals:
• User Manual for i-cut Production Console .
• Get the best out of iPC 2.0
.
Here, a step by step procedure is provided that can be used as a check list.
8.2.
Create Job
In My Jobs List , double-click a file.
My Job Actions -> Create Job .
A new Job is created based upon currently selected file in My Jobs List .
8.3.
Layer Setup
Opened Job -> Layers .
Ensure proper Layer Setup .
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8.4.
Production Setup
Opened Job -> Production Setup .
Verify correct Production Setup :
• Number of Copies
• Accuracy/Speed Prioritization
• Select Reference Point and Job Position
• Step and Repeat
• Registration
• Material Handling
• Tool Head Parking
8.5.
Speed Setting
Opened Job -> Production Setup -> Quality .
Specify if this is a High Accuracy or a High Speed Job .
8.6.
Flute/Grain Direction
Properties Bar -> Flute/Grain Direction .
Verify that the Flute/Grain Direction corresponds to the material.
8.7.
Vacuum Zone Selection
Machine Panel Toolbar -> Vacuum Zones
Kongsberg XP
8
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8
From the Vacuum Zone setup – dialog, configure a suitable vacuum area for the job.
Select Vacuum Zones that corresponds to the outline of your material.
Proper selection is important to achieve the best possible material hold down.
8.8.
Job Execution
Before execution, check this:
1 Verify that Opened Job is ready for production.
Kongsberg XP
2
3
Verify that the Table View display of the Job is reasonable.
Press Pause to reset Safety System .
4
5
6
7
Complete a Table Top Reference sequence to update Tool Height measurement.
Position the material on the Cutting Table .
Press Vacuum On to start the Vacuum Pump .
(If you are running with Automatic Vacuum Control enabled, the pump will start automatically when Start is pressed)
Press Start to execute the Job .
8.9.
Corrugated Production
Corrugated Production without Registration Marks is straight forward following the procedure
described in the Prepare for a Job
- chapter.
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Recommended tooling is described in Esko Tooling Guide .
8.10. Milling Production
Milling Production without Registration Marks is straight forward following the procedure described in
the Prepare for a Job - chapter.
Recommended tooling is described in Esko Tooling Guide .
Note: Milling Jobs should be executed in High Quality mode.
8.11.
Make a Pen Plot
Pen Plot without Registration Marks is straight forward following the procedure described in the
- chapter.
Ensure the Ballpoint Pen is clean and ready to use.
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9. How To Procedures, Advanced
9.1. Optimize vacuum effect
To ensure a well functioning material hold down, reduce the unnecessary air flow as much as needed:
Close vacuum zones that are outside of the material: Machine Panel Toolbar -> Vacuum
Zones, or use Intelligent vacuum control .
Ensure that material and job are placed across a minimum number of vacuum zones . In the leftmost picture all vacuum zones need to be open. If moving the material to the right, two of the zones can be closed, and material hold down is imporved.
Open parts of the vacuum zones can be covered to improve the material hold down further.
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9.2. Cutting Thick Materials
When preparing materials with thickness between 45 – 50 mm (1¾ - 2 in.), the following rules apply:
• No Camera operations are available.
• Disable Measure Material Thickness .
• Disable the Depth Referenced from Top function.
• This function is for Knife Tools only.
Follow the procedure described in the Prepare for a Job - chapter.
Cutting Depth when Depth Referenced from Top is disabled
Note: This function is useful for all materials with an un-even surface.
9.3. Hard Board Production
To prepare hard board materials, the procedure is as follows:
1. Mill through the top layer using HPMU .
2. Cut through the mid-section using the MP HF
VibraCut Knife .
3. Mill through the bottom layer using HPMU .
• Ensure that the milling bit is sharp and proper for the job.
• Ensure that the Knife Blade is sharp and proper for the job.
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9.4.
Multi-pass
Multi-pass is a method to do a job, normally a milling job, in steps, by dividing the thickness into a number of steps (passes). The method can also be used for other tools, like crease wheels , foam knives , V-notch and VariAngle unit . The illustrations below show multi-pass for milling:
1. pass 2. pass 3. pass - mill through and clean the path
Multi-pass creasing is beneficial if you want a deeper crease path.
This is achieved by running one pass with for example 50% depth and a second pass with 70% depth.
Multi-pass milling is beneficial if you want to mill through a thick material, normally thicker than 1 - 1.5
times the diameter of the milling bit .
Multi-pass creasing or milling is available by modifications in the Opened Job -> Layer structure.
Proceed as follows:
1.
Identify the Layer containing the crease or milling line(s) where Multi-pass is wanted.
2.
Make one or more copies of the Layer including geometry.
3.
The Layers will be executed in the listed sequence.
4.
In the Layers , update the depth values to suitable steps.
For execution, follow the procedure described in the Prepare for a Job - chapter.
9.5.
Job
including
Reverse Operation
Reverse Operation is used if operations need to be done from both sides. There are two types of
Reverse Operations :
• Ruler based
• Camera based
Which methode is available, is HW dependant, and described in the following sections. If Crease needs to be done from both sides, ruler based Reverse Operations is commonly used. For Print registration ,
Regmarks need to be read, before sheet is flipped and processed from the other side.
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Menu Bar -> Advanced -> Configure Tools
Menu Bar -> Layer -> Edit Layer ...
Opened Job -> Layers Tab -> Edit Layer
Example below shows configuration of Reverse Operation from Menu Bar -> Advanced -> Configure
Tools
Reverse Operation can also be controlled from a button in
Layers Tab :
Status 1: Selected tool does not currently allow reverse side operation. Can be configured in Configure
Tools dialog.
Status 2: Selected tool allows reverse side operation. Turned off .
Status 3: Selected tool allows reverse side operation. Turned on .
Turn means that the material is flipped over side-to-side.
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Tumble means that the material is flipped over top-to-bottom.
9.5.1. Reverse Operation by Left and Right Rulers
Workflow
Kongsberg XP
Step 1 - the sheet is aligned towards the
Right Ruler .
Reverse Operations are completed.
Step 2 - the sheet
Left Ruler .
The rest of the flipped
Job
and aligned towards the
is completed.
A typical use of Reverse Operation is when you want to add a Crease line on the front side of a material that you normally prepare from the rear side.
This function requires that the table has Left and Right Rulers physically mounted and selected in HW configuration , and that the job is without Regmarks .
9.5.2. Reverse Operation by use of Camera
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9
Workflow
Step 1 -
Camera.
Regmarks and corners are read by the Step 2 - the sheet is flipped (turned or tumbled), and corners are read by the Camera.
All other layers in the Job is processed.
A current limitation of Reverse Operation with Camera is that all layers (except the regmark layer) must be processed from the reverse side.
The function requires that the table is equipped with a Tool Head with Camera, and that the job has
Regmarks .
9.5.3. Reverse Operation in combination with Step and Repeat
Reverse Operations in combination with Step and Repeat and Left and Right Ruler.
For each copy defined by Step and Repeat , you have to move the sheet; first against the Right Ruler , then against the Left Ruler :
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Reverse Operations in combination with Step and Repeat and Camera.
For each copy defined by Step and Repeat , you have to flip the sheet and read Regmarks and corners.
9.6. Work with different Reference Point Settings
Select the Reference Point to use from:
Opened Job -> Production Setup -> Position -> Reference Point
For more information, go here .
9.7.
MultiZone Production
Introduction
In User Manual for i-cut Production Console , general information about MultiZone Production is available.
In this chapter, XP - specific issues are described.
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Kongsberg XP
MZP Panel
Each work zone is equipped with a panel that makes it possible to run the complete MultiZone
Production sequence from the table.
• 1 - Ready Lamp
• 2 - Ready Button
• 3 - Vacuum on Button
• 4 - Vacuum Lamp
9
Vacuum Zones
on page 60
MultiZones
The illustration shows the most actual zones available for MultiZone Production .
Limitations
Work Areas on a MultiZone table
A standard Cutting Table prepared for MultiZone Production , has a limitation caused by the size of the last section, as can be seen by the illustration. See Work Area table below.
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Kongsberg XP
Work area mm/in
Work area, MultiZone Production , standard tabletop mm/in
C24
1680x3200
66x126 in
1680x1450
66x57
C44
2210x3200
87x126
2210x1450
87x57
C60
3210x1600
126.37x63
N/A
C64 C66
3210x3200
126.37x126
3210x4800
126.37x189
3210x1420
126x56
3210x2210
126x87
9.7.1. MultiZone, Workflow
50
- Recommended material flow direction.
Kongsberg XP
9
- Attention Area.
During operation in one zone, parts of the traverse will move into the other zone (photo cell beams, traverse end cover).
To ensure a continous workflow, the operator should be very careful inside the Attention Area , not to trigger the safety system by his body or by material in and out.
Thus, we recommend loading and unloading material from the front- and back end of the table.
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10. System Setup
10.1. Introduction
This chapter will explain functions and parameters that are important for the XP system to run properly.
It is a supplement to the information available from the User Manual for i-cut Production Console .
Examine each step carefully to ensure proper settings:
8
9
6
7
4
5
2
3
One time adjustments completed at the factory
The functions are included here as a reference.
They are not used during normal operation.
If necessary, they should be repeated, as indicated in the function description.
1
Adjust Measuring Station Position
Calibrate Foot on Measuring Station
1
Adjustments to customize the table
2
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10
5
6
3
4
7
10.2. Adjust X1 to X2 Angle
Machine Connection -> Machine Configuration -> Installation _> Adjust X1 to X2 Angle
Use this wizard to obtain correct angle between X axis and Y axis.
Typical use is after maintenance or repair.
Procedure:
1.
Execute the Adjust X1 to X2 Angle function.
2.
Follow the instructions exactly as given by the wizard.
Note: Select a set of drilled vacuum holes (1 and 2) in the table top as reference.
10.3.
Register Table Size
Machine Connection -> Machine Configuration -> Installation _> Register Table Size
This wizard moves the Tool Head from edge to edge of the Cutting Table in order to measure the table size.
Typical use is after maintenance or repair.
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Procedure:
1.
Execute the Register Table Size function.
2.
Follow the instruction given by the wizard.
10.4. Adjust Measuring Station Position
Machine Connection -> Machine Configuration -> Installation _> Adjust Measuring Station
Position
Use this wizard to calibrate the position of the Measuring Station to the system.
Typical use is after maintenance or repair.
Procedure:
1.
Press the Adjust Measuring Station Position button.
2.
Follow the instruction given by the wizard.
3.
Repeat this procedure after maintenance on the Measuring Station .
10.5. Set Ruler Position
Machine Connection -> Machine Configuration -> Installation _> Set Ruler Position
Follow instructions from the wizard.
If your table is equipped with Rulers , please complete the wizard for Left and Right Ruler .
For the table to operate properly an exact registration of the Ruler Positions is necessary.
This is a one time job, but it can be necessary to repeat the procedure if mechanical maintenance has been carried out on the table or traverse.
Correct registration of the Right Ruler is required when Reverse Operations are carried out.
10.6. Set Main Reference Point
Machine Connection -> Machine Configuration -> Installation _> Set Main Reference Position
Follow instructions from the wizard.
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Use this wizard to establish the Main Reference Point (R).
Typical use is after maintenance or repair, if the Main Reference Point has been accidentially moved.
The Main Reference Point is a fixed position on the Cutting Table marked as a cross of drilled holes.
For more information, go here .
10.7.
Map Table Top Surface
Machine Connection -> Machine Configuration -> Installation _> Map Table Top Surface
To assure correct Cutting Depth , the surface of the Table Top is measured in order to create a map.
It is recommended to execute this function if the Cutting Mat is worn out and after the Cutting Mat has been replaced.
Procedure:
1.
If the table is equipped with a Conveyor Belt , move the belt junction away from the table surface.
2.
Execute the Map Table Top function.
3.
Follow the instructions given by the wizard.
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Kongsberg XP
Note: iPC 2.1
: The mechanism of compensating Z height during cutting, based on table top mapping, has been disabled when cutting underlay has been measured to be more than 5mm.
This level is normally reached when milling on top of milling mat and conveyor belt.
This exception was introduced long time ago, before using conveyor belts.
At that time, a (MDF) plate was used as milling underlay. The plate was milled in order to make a perfectly compensated underlay for milling.
As this function is not used anymore, and conveyor belts break the 5 mm limit, iPC now always compensate based on table top mapping.
A registry setting is available to enable the old behavior.
10.8. Calibrate Foot on Measuring Station
Machine Connection -> Machine Configuration -> Installation _> Calibrate Measuring Pad
Use this wizard to calibrate the height level of the Measuring Station .
Typical use is after maintenance or repair; to ensure the tool height measuring system works properly.
Procedure:
1.
Press the Calibrate Foot .
2.
Follow the instruction given by the wizard.
3.
Repeat this procedure after maintenance on the Traverse , Carriage or Measuring Station .
10.9.
Reference Points
and
Coordinate System
Reference Points settings is maintained from:
Menu Bar -> Edit -> Options ...-> Reference Points
All X and Y coordinates in the Input File have the selected Reference Point as origin.
Two modes of operation are available:
• Using Main Reference Point
• Using User Defined Reference Point
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The Main Reference Point position
The Main Reference Point is a fixed position on the Cutting Table marked as a cross of drilled holes.
The User Defined Reference Points are all specified relative to the Main Reference Point .
Thus, moving the Main Reference Point will move these reference points as well.
The Main Reference Point has to be correctly positioned in order to obtain:
• A full Work Area.
• Correct Sheet Feed operation.
• Correct handling of Long Jobs
Using the Main Reference Point during program execution ensures correct operation.
User Defined Reference Points
You can specify User Defined Reference Points .
User Defined Reference Points are used if you want your job positioned in a fixed position on the table
(Rx), but not in the Main Reference Point (R).
A special version of User Defined Reference Point is the Panel Reference Point .
1 Position the
Point .
Laser Pointer in the position where you want your Panel Reference
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10
2 Press the Set Panel Reference Point button on Operators Panel .
The Panel Reference Point is set to current Laser Pointer Position
Kongsberg XP
Rulers and Reference Points
The Ruler System ensures an easy and correct positioning of the material on the table.
The Main Reference Point shall be defined dr = 10 mm/0.39 in. inside the ruler.
When you use the Right Ruler , the Reference
Point will automatically be moved to an identical distance from the Right Ruler , as it is defined from the Left Ruler .
The Right Ruler is normally used for Reverse
Score operations. At the same time the direction of the X axis is reversed.
10.10.
Table Speed
Menu Bar -> Advanced -> Configure Tools ...-> Velocity X/Y
This is the default value for each Tool when Layers are created.
Opened Job -> Edit Layer -> Speed X/Y
Modify Speed for this particular Job.
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Opened Job -> Production Setup -> Quality
Here you specify if this is a High Quality Job or High Speed Job .
10.11.
Table Acceleration
Menu Bar -> Advanced -> Configure Tools ...-> Acceleration
This is the default value for each tool when Layers are created.
Note: Acceleration can be reduced to a % value of the maximum acceleration available.
Opened Job -> Layers -> Edit Layer -> Acceleration
Modify acceleration for this particular Job.
10.12.
Jog Settings
Continuous Jog speed
The Continuous Jog Speed can be reduced to a % value of the maximum jog speed:
Machine Connection -> Machine Configuration -> Setup _> Jog Speed
Specify low and high Jog Speed
Incremental Jog Step Size
The size of the Incremental Jog movements can be customized.
Machine Connection -> Machine Configuration -> Setup -> Incremental Jog
Specify Step Size to be used.
Jog Directions
Machine Connection -> Machine Configuration -> HW configuration ->Operator panel
Specify operator panel position. This will define the jog directions for the buttons on the operator panel .
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10.13. Set Table Top Reference
Menu Bar -> Machine -> Set Table Top Reference
Follow instructions from the wizard.
Machine Connection -> Machine Configuration -> Installation _> Table Top Reference
Follow instructions from the wizard.
Machine Panel Toolbar -> Table Top Reference
Use this function to complete a Tool Height Reference calibration.
The Tool Height is measured in current position and the reference to the table top surface is updated.
This calibration is the basis for Tool Height calculation.
The Table Top Reference function should be carried out:
• After mechanical adjustments of traverse or tool head.
• When cutting through material is not working properly.
• After any change of cutting / milling underlay, for instance, after adding or removing the milling underlay.
Procedure:
1.
Remove all materials from the table surface.
2.
Measure on top of the cutting underlay or conveyor belt.
3.
If the table is equipped with a conveyor belt, avoid measuring directly on the belt junction.
4.
Execute the Table Top Reference function.
5.
In the wizard, press OK to start measurement.
10.14. Vacuum Setup
10.14.1. Vacuum Zone Configuration
Machine Connection -> Machine Configuration -> HW Configuration -> Vacuum Setup
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This is a dialog where the Vacuum Zone Configuration for the actual machine is specified.
This setup is a one-time job as long as the Vacuum Zone Solution on the machine remains unchanged.
The setup should correspond to the actual hardware.
The selected setup will determine which Vacuum Zone Configuration that will be available in the User
Interface .
Machine
XP20
Zone Configuration Vacuum Configuration
#7
XP24
XP44
#2
#2
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10.15. Milling Unit Setup
Machine Connection -> Machine Configuration -> HW Configuration -> Milling Unit setup
From the Milling Unit setup dialog, maintain the following parameters:
Specify Milling unit
If a milling unit is mounded, spedify milling unit type.
If no milling unit is mounted, select None .
COM-port
The physical COM-port used for communication with the control unit is specified.
Note: The control unit needs to be connected to a genuine COM port. If connected to a USB-to-COM adapter, the communication will fail.
These functions are used only after a hardware modification.
10.16. Conveyor Belt Control
Machine Connection -> Machine Configuration -> HW Configuration -> Conveyor
Specify if the machine is equipped with Conveyor Belt .
10.16.1. Split Sheet Feed
62
Sheet in Load Position Sheet Load, step 1 Sheet Load, step 2
In some occasions, the sheet unloaded from the cutting table can trigger the photo cell safety system.
To avoid this, the sheet feed movement is divided into two steps.
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10.16.2. Sheet Feed Correction
If the Conveyor Belt feed length needs adjustment, use this function to adjust the movement of the
Conveyor Belt to be shorter or longer.
10.17. Board Size
Not implemented yet
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11
11. Tool Configuration and Adjustment
Machine Connection -> Tool Configuration
Kongsberg XP
The Tool Configuration dialog is used for all tool settings and adjustments.
Select tool and function.
11.1.
Tool Configuration
The XP machine offers two different tool positions, P1 and P2, where different interchangeable tools can be mounted.
In addition, there are separate fixtures for Laser Pointer , Measuring Foot , Camera , Drill and Pen Tools :
L - Laser Pointer
M - Measuring Foot
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P1 - P1 tool position, see table below
C – Camera position
P - Pen / Drill / Ink Tool holder position
P2 - P2 tool position, see table below
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11
The following tool configurations are available:
Tool Type
HDU - Heavy Duty Unit
Dual HDU
FCU -
HPMU
-
Foam Cutting Unit
– High Power Milling Unit
VibraCut Knife Tool
HF VibraCut Knife Tool
HiForce Knife Tool
RM Knife Tool
RotaCut Knife Tool
PressCut
Psaligraphy knife tool
CorruSpeed knife tool
Braille Tool
Dual Heavy Duty Unit
VariAngle unit
Available Tool Inserts
HD Crease , V-notch Knife , HD Knife Tool ,
Bevel knife , Perforation Wheel
HD Crease , V-notch Knife , HD Knife Tool ,
Bevel knife , Perforation Wheel
Standard adapter and long adapter for short knife blades (optional)
P1
Yes
Yes
Yes
P2
Yes
Yes
Yes Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Drill/Pen Holder
Laser pointer
Measuring Foot
Camera system
Drill Tool , Ballpoint Pen , Ink Tool ( Fibertip
Tool )
Yes (1)
Yes (2)
Yes (2)
Yes (2)
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This table shows correct position for the different tools.
The tool configuration; the tools available depends upon the actual delivery.
Notes:
(1): An optional Tool Insert Position is required for these tools.
(2): These units are permanently fixed to the P1 tool position.
The Fast Tool Adapter makes it possible to attach tools intended for P2 into P1.
Note :
HF-Vibra Cut Knife Tool fits in P1 as well as P2, but the Fast Tool Adapter shall not be used.
PressCut tool can not be used with the Fast Tool
Adapter (fits in P2 only).
11.2.
Tool Names
Factory Tool Name
The Tool Type mounted is identified by hardware codes inside each tool.
The identified tool is called Factory Tool Name
The mounted tools are maintained by:
Machine Connection -> Tool Configuration
Current tool configuration is displayed under Identified tools .
When a new tool is inserted, it will be identified to the system automatically.
By default the system creates a username from the tool type and its serial number. E. g. a knife with serial number 3020 will be named Knife 20
User Tool Name
Menu Bar -> Advanced -> Configure Tools
From this dialog, you can give each tool a nickname.
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11.3.
Adjust Active Tool
Machine Connection -> Tool configuration -> Adjust Active Tool
Follow instructions from the wizard.
From the Adjust Active Tool – dialog, all Tool Adjustment Wizards are executed.
The following procedures are general descriptions of how to adjust the tools.
See the description of each Tool Type for more specific information:
We recommend using a sheet of Folding Carton material, 5-6 mm / 0.2 inch, when executing the adjustments.
Note: All tools need to be adjusted in the position they will be used.
Before any adjustment, complete a Table Top Reference function.
11.4. Lag Settings (for Rotating Tools)
Machine Connection -> Tool configuration -> Adjust Active Tool -> Lag Settings
Follow instructions from the wizard.
1.
In the Configure Tool dialog , select the Tool to be adjusted.
2.
Press the Adjust Active Tool button to enter the Wizard Selection dialog .
3.
Select Lag Settings
4.
Follow the instructions given to enter correct values.
5.
Repeat the procedure for all rotating tools.
Lag Test
Machine Connection -> Tool configuration -> Adjust Active Tool ->Lag Settings->Lag Test
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Run this wizard to obtain correct Knife Lag value.
Follow the instructions in the dialog.
Add the measured value to the displayed value.
Circle Lag
Circle quality is determined by a parameter called Circle Lag . The parameter value will vary depending upon the actual material.
Therefore, the adjustment is located in the Opened Job -> Edit Layer dialog
11.5.
Tool Height Calibration
Machine Connection -> Tool configuration -> Adjust Active Tool -> Tool Height Calibration
Follow instructions from the wizard.
C systems are equipped with Automatic Tool Height Calibration .
Thus, the system will run without any manual height calibration.
If you would like to add an offset to the measured height, use the Tool Height Calibration dialog:
1.
Select the Tool to be adjusted
2.
Press the Adjust Active Tool button to enter the wizard selection dialog.
3.
Select Tool Height Calibration
4.
Follow the instructions given by the wizard, step by step.
5.
Repeat the procedure for all tools.
Typical use of this function is to add depth in order to ensure proper through-cut in dicult materials.
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11.6. Rotation Adjustment (for Rotating tools)
Optimal Angular Offset may vary with different material strength and thickness.
The adjustment can be done using the adjustment wizards, or by a manual adjustment procedure:
Adjustment using Wizard
Machine Connection -> Tool configuration -> Adjust Active Tool -> Rotation Adjustment
1.
Select the Tool to be adjusted.
2.
Press the Adjust Active Tool button to enter the wizard selection dialog.
3.
Select Rotation adjustment.
4.
Follow the instructions given by the wizard, step by step.
5.
Repeat the procedure for all Tools mounted.
Manual Adjustment
Machine Connection -> Tool configuration -> Adjust Active Tool -> Manual Adjustment of...
Follow instructions from the wizard.
1.
Place an appropriate test material on the table, and switch Vacuum On .
2.
From Machine Connection -> Tool Configuration , select one Tool .
3.
Press Adjust Active Tool to enter the Wizard Selection Dialog .
4.
Select Manual Adjustment of Center Offset and Angle .
5.
Enter value for the Angular Offset and select Activate .
6.
Note that the Tool will rotate as the new value is activated.
7.
Press Tool Override Down , and Jog approximate 10 cm to make a test cut.
8.
Press Tool Override Down once more to lift the Tool again.
9.
Press Tool Override Down once more to lower the Tool again.
10.
Note how the knife enters into the material.
11.
Press Tool Override Down once more to lift the Tool again.
12.
If knife enters exact into the cut, the angle is correct; select Finish to exit.
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13.
If seen in the cutting direction, the knife enters to the left of the cut, the Angular Offset Value should be decreased. Repeat from point 5.
14.
If seen in the cutting direction, the knife enters to the right of the cut, the Angular Offset Value should be increased. Repeat from point 5.
11.7. Center Offset Adjustment
The adjustment can be done using the Adjustment Wizards , or by a Manual Adjustment procedure:
Adjustment using Wizards
Machine Connection -> Tool configuration -> Adjust Active Tool -> Center Offset Adjustment
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1.
Put an appropriate test material, that means a thin paper on the table (any significant material thickness will create a misleading offset in this wizard), and switch vacuum on.
2.
Select the Tool to be adjusted.
3.
Press the Adjust Active tool button to enter the wizard selection dialog.
4.
Select Center Offset Adjustment .
5.
Follow the instructions given by the wizard, step by step.
6.
Repeat the procedure for all Tools mounted.
Manual Adjustment
Machine Connection -> Tool configuration -> Adjust Active Tool -> Manual Adjustment of...
Follow instructions from the wizard.
1.
Place an appropriate test material on the table, and switch Vacuum On .
2.
From Machine Connection -> Tool Configuration , select one Tool .
3.
Press Adjust Active Tool to enter the Wizard Selection Dialog .
4.
Select Manual Adjustment of Center Offset and Angle .
5.
Enter value for the Center Offset and select Activate .
6.
Note that the Tool will move as the new value is activated.
7.
Press Tool Override Down , and Jog approximate 10 cm to make a test cut.
8.
Press Tool Override Down once more to lift the Tool .
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9.
Press the Jog button for the return direction shortly, just to turn the Tool .
10.
Press Tool Override Down once more to lower the Tool , and Jog the same distance back.
11.
Press Tool Override Down once more to lift the Tool .
12.
The two cuts should follow exactly the same path.
13.
If exact, the Center Offset is correct, select Finish to exit.
14.
If not, modify the Center Offset Value and repeat from point 6.
11.8. Tool Offset
Machine Connection -> Tool configuration -> Adjust Active Tool -> Offset Adjustment
The Laser Pointer is the reference:
1.
Place an appropriate test material on the table, and switch Vacuum On .
2.
From Machine Connection -> Tool Configuration , select one Tool .
3.
Press Adjust Active Tool to enter the Wizard Selection Dialog .
4.
Select Offset Adjustment .
5.
A cross is made by the Tool to be adjusted.
6.
The Laser Pointer is positioned in the center of the cross.
7.
If necessary, jog the Laser Spot into the center of the cross.
8.
Follow the instructions given by the wizard, step by step.
11.9. Knife angle calibration
The automatic calibration of the notch angle will be completed every time the machine starts, or when an adapter is changed. It can also be activated from the Tool configuration dialog if necessary:
Machine Connection -> Tool configuration -> Adjust Active Tool -> Notch Angle Calibration
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The purpose of the calibration is to make sure the accuracy of the knife angle is optimal
Manual notch angle Offset
Machine Connection -> Tool configuration -> Adjust Active Tool -> Manual Adjustment
An extra manual adjustment of the notch angle is possible. Please note that this offset will be added to the calibrated value found in the automatic calibration procedure.
1.
From Machine Connection -> Tool Configuration -> Select the VariAngle unit
2.
Click the Adjust Active Tool button
3.
Select Manual Adjustments then click Next
4.
Go to the notch angle area
5.
Enter a positive or negative value in the Zero Offset (degrees) box, or use the up/down arrows
6.
Click Activate and then Finish to store the offset
11.10. Maintain Tool List
Machine Connection -> Configure Tools -> More ...
The More ... dialog contains selections to Ignore , Delete or Add to the Tool List .
The Tool List contains Tools that you can select for the available Tool Positions .
Ignore Automatic Tool Identification
Ignore Automatic Tool Identification may be used when the Automatic Tool Detection fails, and manual tool selection is necessary.
If Ignore Automatic Tool Identification is checked, Tool Setup remains unchanged after:
• Table Zero Position sequence
• Identify Tools function
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Delete Tool
Use Delete Tool when a Tool is no longer in use.
The deleted Tool will no longer be available in the Tool List in the Edit Layer dialog.
Add Tool
Use Add Tool to
• Add new Tools
• Add tools that fails during Automatic Tool Detection
The Tool is added to the Tool List .
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12. Tooling System
12.1. Introduction
Knife Blades and Milling bits are extremely sharp.
Take care when handling Knife Tools and Milling bits.
Laser Radiation.
Do not stare into beam!
The tool head is equipped with a class II laser pointer. Emitted laser power < 1 mW.
In this chapter, all tools are explored:
• General description
• How to operate
• How to adjust
12.2. Tool Handling and Care
All Tools are precision instruments and should be treated as such to ensure proper operation.
Take special care when:
• Tools are inserted or removed from their stations. No excessive force should be applied.
• Tools should not come in contact with hard surfaces while removed from their stations either temporarily or for storage.
• The Tools and their stations should be kept clean with a soft brush.
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12.3. How to Replace a Tool
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12
When mounting a tool onto the P1 or P2
Tool Positions , ensure that the Guide
Pins and the electrical connector fits those on the bracket.
Use an Allen Key , 6 mm, to fix the tool.
Ensure both screws are properly fixed.
12.4. Two or more tools of the same type
Each tool is identified to the system by Tool Type .
In addition, it is possible to identify up to four different tools of the same type.
One example:
If you have two different Static Knife Tools , you can specify one to be number 1 and one to be number
2.
In this way, all Adjustment Parameters will be stored and recalled automatically as the tool is mounted onto the machine.
How to define individual Tool Numbers
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Inside each Tool , there is a Tool Board .
By means of dip-switches, you can specify 4 unique Tool Numbers .
The different Tool Numbers are defined as follows:
Tool Number
Tool 1
Tool 2
Tool 3
Tool 4
Tool Board switch setting
1 & 2 off
1 on & 2 off
1 off & 2 on
1 & 2 on
Note: There are some restrictions, see Technical Manual for more information.
12.5.
Measuring Station
XP is equipped with a Measuring Station :
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The Measuring Station eliminates the manual adjustment of tool height.
The Measuring Station covers the following functions:
• Calibrates the Measuring Foot .
• Automatically measures the height of the tool tip.
If you, for any reason, would like to add an adjustment value to the measured value, a height adjustment dialog is available from the Tool
Configuration menu.
The Measuring Sequence is carried out as follows:
• During the first Table Zero Sequence after Power On .
• After any Tool change and the Tool is not calibrated.
• After the Safety System has been broken for 30 sec. or more.
• After the Servo System has been off for 30 sec. or more.
• During the Table Zero Sequence if Incremental Jog is selected.
Tool Depth and Measuring Station
Be aware how the Measuring Station is working; it is the tool tip that is measured.
Depending upon the actual tool, it might be necessary to add depth in order to achieve cut or drill through the material.
Additional depth is entered in two ways:
• The general depth of a Tool is entered from
Machine Connection -> Tool configuration -
> Adjust Active Tool -> Tool Height Calibration .
• The Job specific depth is entered from
Opened Job -> Edit Layer
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12.6. HDU -
Heavy Duty Unit
Kongsberg XP
HDU with ø150 mm Crease Wheel
The Heavy Duty Unit is a single position Tool Head specially prepared for V-notch and HD Knife tools .
In addition, the Tool Head can be equipped with a ø150 mm Crease Wheel , crease adapter and perforation wheel.
For detailed description, see separate chapters for
•
•
•
•
•
12.6.1. Crease Wheel ø150 mm
Description
A ø150 mm Crease Wheel mounted on an Heavy Duty Unit .
This Crease Wheel has the equivalent of
50 kg [110 lbs] of down-pressure.
The additional pressure, combined with the large frontal area of the big wheel enables excellent crease quality in heavy duty Corrugated Board and even permits creasing board with high recycle content without breaking the liner.
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How to mount / dismount Crease Wheels
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A broad range of Crease Wheels with different shapes is available.
Insert / remove the Latch Pin .
Insert / remove the Cotter Pin .
Tool Adjustment
For this tool, complete the following adjustments:
Adjustment
Lag Setting
Tool Height
Tool Rotation
Center Offset
Tool Offset
Description
The Lag value depends upon the Blade Adapter .
Nominal value is 0 mm.
Measured automatically, possible to add an Offset Value .
Adjust Tool Angle tangential to Moving Direction .
Adjust Tool sideways until centered.
Adjust offset relative to Laser Pointer .
For more information about how to run the Adjustment Wizards
, see the Tool Configuration chapter
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12.6.2. V-notch Knife Tool
Description
Kongsberg XP
The V-notch Knife Tool mounted on a Heavy Duty Unit .
How to insert / remove the V-notch Knife Tool
1 Turn the V-notch Knife Tool correctly to fit the Guide Pin .
i
2 Insert the two Latch Pins .
3 Insert the Cotter Pins .
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How to replace a Knife Blade
Warning: Sharp tool
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This picture shows how the Knife Blade is aligned using two Guide Pins (a and b) beneath the blade clamping.
1.
Loosen the two screws (b) of the
Knife Blade clamping.
2.
Carefully remove the blade (a).
3.
Insert a new Knife Blade and make sure that it is aligned with the Guide
Pins (c).
4.
Mount the new tool. (Note the position of the Guide Pin ).
5.
Ensure that the tool height is calibrated on the Measuring Station .
About Tool Adjustment
• For the V-notch Knife , we recommend the manual procedures for Tool Rotation and Center Offset adjustment.
• When adjusting Tool Rotation and Center Offset , use a thin Folding Carton material.
• Remember that you should look at the bottom side of the material for correct alignment.
• The adjustment depends upon the actual material due to weight, structure and thickness.
• For optimal result, a fine tuning of the adjustments in the actual material should be carried out.
For this Tool , complete the following adjustments:
Adjustment
Lag Setting
Description
The Knife Lag depends upon the Blade Adapter .
Nominal value is 0-7 mm.
Tool Height
Tool Rotation
Measured automatically, possible to add an Offset Value
Adjust Tool Angle tangential to Moving Direction .
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Adjustment
Center Offset
Tool Offset
Description
Adjust Tool sideways until centered.
Adjust offset relative to Laser Pointer .
For more information about how to run the Adjustment Wizards
, see the Tool Configuration chapter
How to set the depth of the V-notch Knife
1.
The default depth of the V-notch Knife is cut through the entire material.
2.
To make adjustment to the depth, go to Opened Job -> Edit Layer .
3.
Normally the cut should extend down to just above the Bottom Liner .
V-notch Knife Cut Direction
The blade angle and the cut direction must be taken into account when cut jobs are prepared.
The arrow indicates the Cut Direction .
Different angles
A wide range of V-notch knives is available, providing different knife angles, v: 15 o
, 22.5
o
, 30 o
, 45 o
, 47.5
o
.
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V-notch knife tools, modes of operation
Opened Job > Layers Tab > Edit Layer
Menu Bar -> Layer -> Edit Layer ...
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Note:
V-notch Knife Adapters are available for different knife angles: 15 o
, 22.5
angle from 0 to 60 o
.
o
, 30 o
, 45 o
, 47.5
o
. There is also a VariAngle unit available for cutting any
In this chapter, a 45 o
knife angle is discussed.
The programming and operation will be similar for other angles.
V-notch specific parameters
Rotational compensation
Rotational compensation is used to optimize V-notch / Bevel Cut quality in challenging materials and use cases. This feature will pre-load the knife blade and overcome mechanical flexibility in the system.
Notch angle
Notch Angle is used for the VariAngle unit only, and determines the angle of the blade into the material.
0 o is a vertical cut. For V-notch knifes , angle is determined by type of V-notch knife mounted.
V-notch Cut
Performs a single angled cut
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Geometry
Kongsberg XP
V-notch Crease
This is the default mode if neither V-notch cut nor
Waste Cut are enabled.
Performing two cuts in opposite direction to create a folding notch.
Width Offset
Width Offset is used to adjust the width between the two cut lines along and across flute when
Crease is selected.
Waste Cut
Waste Cut adds a third cut line to ease removal of waste.
Note: This function is working along Y only. Flute direction must be along Y. The numbers indicate sequence of operation.
When the knife angle is 45 o and you cut through the material, the width of the cut is W = 2 x h.
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Folding
If you prepare a material for folding, the following rules applies:
• Adjust the cutting depth to just above the bottom liner.
• Adjust the cutting width (W) by the adjustment parameter Width Offset. Nominally, the width of the cut has to be increased by Width Offset = - 2 x bottom liner thickness.
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• Width Offset limitations: -50 mm < Width Offset < +10 mm / -2 in < Width Offset < +0.4 in.
• Decide if Waste Cut function is needed, mostly needed for corrugated plastics.
This illustration shows how the parameter dW is used to ensure a nice folding result.
Waste Cut function, adjustment
This illustration shows a typical use of
Waste Cut function.
The middle wall is not cut by (2) or (3), making the material impossible to fold.
The Waste Cut function (1) cut the middle wall and you can fold the material nicely.
Negative and positive adjustment direction vs. cut direction
12.6.3. HD Knife Tool
Description
The HD Knife Tool mounted on HDU .
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The HD Knife Tool is used for rigid board such as ReBoard and Triple Wall material.
The Tool is limited to Straight Lines longer than 50mm (2”).
The Tool is prepared for special, trapezoid shaped Knife Blades .
How to replace a Knife Blade
Warning: Sharp tool
This picture shows how the Knife Blade is aligned against two Guide Pins .
Use these two screws to fix / release the Knife Blade .
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How to insert / remove the HD Knife Tool
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1 Turn the HD Knife Tool correctly to fit the Guide Pin .
2 Insert the two Latch Pins .
3 Insert the Cotter Pins .
Tool Adjustments
For this tool, complete the following adjustments:
Adjustment
Lag Setting
Description
The Knife Lag depends upon the Blade Adapter .
Nominal value is 10 mm.
Tool Height
Tool Rotation
Center Offset
Tool Offset
Measured automatically, possible to add an Offset Value .
Adjust Tool Angle tangential to Moving Direction .
Adjust Tool sideways until centered.
Adjust offset relative to Laser Pointer .
For more information about how to run the Adjustment Wizards
, see the Tool Configuration chapter
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12.6.4. Crease Adapter
Kongsberg XP
Using a Crease Adapter allows for smaller crease wheels or crease blades used on HDU.
Adapters are available for ø15mm, ø26 mm and
ø60mm crease wheels. There is also a separate adapter for crease blades.
Mount crease adapters in HDU by using two Latch pins with accompanying cotter pins.
12.6.5. Perforation Wheel ø60 mm
Use Perforation Wheel to prepare Perforation Cut
Lines or to assist creasing at high speed.
Perforation wheels with different pit to land ratios are suitable for multiple purposes in different materials.
Before August 2019, Esko’s portfolio of
Perforation wheels had four different sizes: 3:3 mm, 5:5 mm, 7:5 mm and 10:10 mm
From August 2019, the portfolio was extended.
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Perforation Wheel assembly
Warning: Sharp tool
Parts in assembly
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Ensure the path is clean.
Fix cover properly.
Push/pull the Perforation Wheel in/out from the
60 mm crease adapter.#
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Tool Adjustment
For this tool, complete the following adjustments:
Adjustment
Lag Setting
Description
The nominal value for Perforation wheels is 0 mm.
Tool Height
Tool Rotation
Center Offset
Tool Offset
Note : The Lag value can be used to adjust overshoot and Lead-in of
Perforation Cut Lines .
Measured automatically, as separate tool, possible to add an Offset Value .
Note : The height measurement of the Perforation Wheels depends on the orientation of the wheel (pit or land facing measuring station). This becomes more critical with bigger pits.
Adjust Tool Angle tangential to Moving Direction .
Adjust Tool sideways until centered.
Adjust offset relative to Laser Pointer .
Tip : When adjusting Tool Height for Perforation wheels or Crease wheels , move the tool outside of the material surface. Set the Tool Height so that the Tool tip touches the Table Top Surface before manually jogging the tool through the material. Complete wizard and inspect crease/perforation result
(should yield a good quality crease or perforate all the way through material).
For more information about how to run the Adjustment Wizards
, see the Tool Configuration section.
12.6.6. Bevel Knife 45
Bevel Knife is a special-purpose tool for 45 degree angled cuts.
Lag = 3.5 mm / 0.14 in.
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How to replace a Knife Blade
Warning: Sharp tool
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12
• Loosen the two screws holding the blade clamp.
• Pull out the old Knife Blade .
• Insert the new blade.
• Ensure the blade align exactly with the alignment pins.
• Fix the blade clamp.
At left, the clamp is removed just to show how to align the Knife Blade .
After a blade change, the tool depth should be checked again.
How to set the cutting depth of the Bevel Knife
The default cutting depth for Bevel Knife is cut through the entire material.
Define the depth of the bevel cut in the Layer Setup .
Normally, the cut should extend down to just above the bottom liner.
About tool adjustment
For the Bevel Knife , we recommend the manual procedures for tool rotation and centre offset adjustment.
Use a thin Folding Carton material when adjusting tool rotation and centre offset.
Remember that you should look at the bottom side of the material for correct alignment.
The adjustments depend upon the actual material due to weight, structure and thickness.
For optimal result, a fine tuning of the adjustments in the actual material should be carried out.
For more information about how to run the Adjustment Wizards
, see the Tool Configuration chapter
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12.7.
Foam Knife
Description
Kongsberg XP
The Foam Knife Tool Head is mounted onto the P1–position.
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Note: Be careful where to place the Foam Knife Tool when not in use.
If the Tool Head is left on a table surface, the Knife Blade might be exposed, as the material hold down wheels moves up.
How to replace a Knife Blade
Warning: Sharp tool
Loosen the fixing screw, replace the Knife Blade and fix it again.
No additional adjustments are necessary, as the tool height is measured automatically.
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A set of Knife Protection Handles are available.
Use them for safe knife handling.
When not in use, protect the Knife Blade using the handle.
How to replace the Knife Adapter
Loosen the fixing screw, replace the adapter and fix it again.
No additional adjustments are necessary, as the tool height is measured automatically.
Disable Material Thickness Measurement
Opened Job -> Layers -> Edit Layer .
For the Foam Knife Tool , the Disable Material Thickness Measurement function is available.
Use this function if:
1.
Your foam material is too soft for the measuring system.
2.
The surface of your material is un-even.
When the Disable Material Thickness Measurement function is enabled, the following rules applies:
• Depth is referenced from bottom (top of cutting underlay).
• During Tool Up movements, the knife is lifted to its top position.
Cutting Quality
To obtain best quality when cutting details, as small circles, we recommend:
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• Reduce the Cutting Speed (from Opened Job -> Layer ).
• Cut in two or three passes, each pass going a step deeper (
Tool Adjustment
For this tool, complete the following adjustments:
Adjustment
Lag Setting
Description
The Knife Lag depends upon the Blade Adapter .
Nominal value is 3 (5) mm.
Tool Height
Tool Rotation
Center Offset
Tool Offset
Measured automatically, possible to add an Offset Value .
Adjust Tool Angle tangential to Moving Direction .
Adjust Tool sideways until centered.
Adjust offset relative to Laser Pointer .
For more information about how to run the Adjustment Wizards
, see the Tool Configuration chapter
12.8.
Dual HDU
-
Dual Heavy Duty Unit
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P1 – P1 tool positions, see table below
P2 – P2 tool position, see table below
C- Camera Position
P – Pen/Drill/Ink Tool holder position
P1.1 – Position 1 of the Dual HDU , equal to the standard HDU.
P1.4 – The secondary position of the Dual HDU (and thereby the 4th tooling position on the C-platform), specifically prepared for 60 mm wheel inserts.
The Dual Heavy Duty Unit is a dual position Tool head specially prepared for HD Crease and perforation tools. In addition, it is prepared for V-notch and HD Knife Tools .
See the table for possible tool combinations:
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P1.1
P1.4
Comments
150 mm Crease Wheel
150 mm Crease Wheel
Perforation Wheel For Crease and Perforation
60 mm Crease wheel For different points or pressure distribution
15 / 26 / 60 mm Crease Adapter Perforation Wheel For Crease and Perforation
15 / 26 / 60mm Crease Adapter 60 mm Crease wheel For different points or pressure distribution
Crease
Crease
Blade
Blade
Perforation Wheel (with the 60 mm Crease Adapter )
HD 17 Knife
HD 17 Knife
Bevel Knife
Perforation Wheel For Crease and Perforation
60 mm Crease wheel For different creasing types
Perforation Wheel For different perforation patterns
Perforation Wheel
60 mm Crease wheel
Perforation Wheel
Bevel Knife
HD 30 Knife
V-notch inserts (all angles)
60 mm
N/A
N/A
Crease wheel
Cannot combine HD30 with 2nd tooling position
Cannot combine V-notch with 2nd tooling position
For detailed descriptions of the P1.1 tooling-inserts, see separate section for HDU – Heavy Duty Unit:
• V-notch Knife
• 150 mm Crease Wheels
• Crease Adapter
• Perforation Wheels
• Bevel Knife
For detailed description of P1.4 and the new method for mounting/dismounting tools, see separate sections below:
•
Dual HDU HD Perf Position on page 96
•
New mounting procedure for HD insert tools on page 98
Note :
The Dual HDU unit consists of two separate tool positions. Therefore two separate Line Type inputs for iPC are needed for translation into two separate Layers . This is similar to that one Layer for the
Knife Tool and one Layer for the Crease Tool is needed. In case a Perforation Wheel is used in the secondary position of the Dual HDU unit, continuous Line Type will be needed, instead of a dashed line:
The Perforation Wheel does not need to move up and down while converting.
Refer also User manual for iPC , section Before we start .
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12.8.1. Dual HDU HD Perf Position
Description
The Dual HDU HD Perf tool position is for 60 mm wheels,
Perforation or Crease . The position is identified by the system as
“HD Perf”.
It delivers the equivalent of 50 Kg [110 lbs.] downforce.
The HD Perf position can handle cut depths up to 6 mm.
This position was developed to deliver additional flexibility and to allow creasing and perforating heavy duty materials with the use of one tool unit.
Perforation Wheel mounting for the Dual HDU
The Perforation Wheels are locked in place using a Locking screw when mounted in the HD Perf position. This is to ensure that the wheel is not pulled out when converting heavy materials.
Note : Always tighten the Locking screw .
Safety warnings
Warning: Sharp tool
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Be aware of the tight gap between HD Crease and HD Perf.
Be aware of sharp Perforation
Wheel when mounting tools in
P1.1.
Be aware of sharp knifes in P1.1
when mounting HD perf.
Curved geometries
If using the HD Perf position for circles or curves of any kind, make sure to convert in a clockwise direction. This will give a better perforation quality .
Tool Adjustment
For this tooling position, complete the following adjustments:
Adjustment
Lag setting
Tool Height *)
Tool Rotation
Center offset
Tool Offset
Description
The nominal value for Perforation Wheels is 0 mm. Note : The lag value can be used to adjust overshoot and Lead-in of Perforation Cut Lines .
Measured automatically, as separate tool. It is possible to add an Offset value.
Note : Height measurement of Perforation Wheels on the Measuring Station depends on the orientation of the wheel (“pit” or “land” facing Measuring
Station ). This becomes more critical with bigger pits.
Adjust Tool Angle tangential to Moving Direction .
Adjust Tool sideways until centered
Adjust Offset relative to Laser pointer
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*) Tip : When adjusting Tool Height for perforation or Crease wheels , move the tool outside the material surface. Set the height so that the tool tip touches the table top surface before manually jogging the tool through the material. Complete wizard and inspect Crease /perforation result (should yield a good quality Crease or perforate all the way through material).
For more information about how to run the Adjustments Wizards, see
on page 64.
Note :
• For the Dual HDU , remember to always complete Tool Adjustments for the P1.1 position first.
• The HD Perf position is adjusted as a separate tool, despite being connected to the main Dual HDU structure.
• The HD Perf position is not compatible with V-Notch Knife Tool or HD30 knife. The HD Perf position will automatically be disabled from SW if one of these tools are identified in tooling position P1.1
• The tool mounted in the HD Perf position must be removed before inserting a V-Notch Knife Tool in position P1.1 (will not fit if not).
12.8.2. New mounting procedure for HD insert tools
Inserting the tools into the Tool holder fork follows the same procedure as described in the separate tool insert sections. The procedure for fixing them in place is however different for the Dual HDU :
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Insert the Locking Pin from one side until it snaps in place. No Cotter pin is needed from the other side.
For HD inserts other than HD Crease , remember to use both pins.
Note : Check that the pin is inserted all the way in.
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To mount V-notch in the Dual HDU , remove wheel from HD Perf position first. It is not possible to correctly mount the V-notch tools with Perforation Wheel still mounted.
HD Knife tool safety cover
The HD Knife tools come with an additional safety cover. If you have bought a HD Knife Tool before Q3
2019, the axle-bar that holds this safety-cover must be exchanged (if you want to use your HD Knife
Tool in the Dual HDU ). Find the new axle-bar attached to your Dual HDU kit.
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12.9.
VariAngle unit
12.9.1. Introduction
The VariAngle unit is a tool for position P1 on Cxx and XP platform. It is specially prepared to cut at different angles (also known as V-notching). The tool can automatically change the angle of the knife between 0 and 60 degrees, in 0.5-degree steps, where 0 degrees is vertical.
12.9.2. Safety precautions
Warning: Sharp tool
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Please be aware that during a job, the knife might point straight towards the operator.
Note : Never approach tool while machine is running. Wait until the machine is in a safe state.
To protect the operator, the knife will move to the max angle, and the tool will turn backwards when the VariAngle unit is not active and another tool is selected.
In the case of the tool being selected while the machine is not running a job, the knife will point straight down towards the table.
Note : Never put your hand close to the tool while the tool is moving.
12.9.3. Tool description
1. Knife blade for cutting of thicker board materials. There are different blade lengths that fit different adapters.
2. Adapter.
The adapter is fixed to the tool by a thumb screw.
3. Motor cap to protect the motor. Do not remove; do not use for lifting or adjusting the tool.
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How to mount / dismount knife blades to adapters
The knife blade is fixed to the adapter with a mounting plate with guide pins and screws.
The guide pins ensure correct combination of knife blade and adapter, wrong combination will not fit.
Note : For safety reason, always dismount the adapter from the tool before changing knife blades.
Warning: Sharp tool
How to mount / dismount adapter with knife blade to the tool
Adapters are fixed with a thumb screw. Loosen the screw and pull out the adapter.
Note: For safety reason, always mount the tool to the machine before mounting adapter with knife blade.
And further : Always remove the adapter with knife blade before dismounting the tool from the machine.
Warning: Sharp tool
12.9.4. Description of knife blade adapters
The knife blade adapter comes in two versions; standard adapter for standard/long knife blades and an optional long adapter for short knife blades. The standard adapter can always be used; the long adapter gives better results in thin materials. The adapters are automatically recognized by the machine, and will have separate adjustment values. Knife blades will fit in dedicated adapters only, preventing wrong combinations of adapters and knife blades.
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Standard adapter, for standard/long knife blades, included with the tool.
• Straight cut up to 30 mm / 1.18 in. material thickness
• V-notch cut at 45 degrees up to 20 mm / 0.79 in. thickness
• V-notch cut at 60 degrees up to 16 mm / 0.63 in. thickness
Long adapter for short knife blades, optional.
This adapter is specially suited for thin materials, and it gives perfect results in thicknesses of 5-10 mm / 0.2-0.39 in.
• Straight cut up to 16 mm / 0.63 in. material thickness
• V-notch cut at 45 degrees up to 13 mm / 0.51 in. thickness
• V-notch cut at 60 degrees up to 6 mm / 0.24 in. thickness
The table describes the limitations for the two adapters, with regard to material thickness and notch angle :
• Orange: Standard adapter with standard/long knife blades
• Green: Long adapter with short knife blades.
6 mm / 0.24 in.
8 mm / 0.31 in.
10 mm / 0.39 in.
12 mm / 0.47 in.
14 mm / 0.55 in.
16 mm / 0.63 in.
18 mm / 0.71 in.
20 mm / 0.79 in.
22 mm / 0.87 in.
24 mm / 0.94 in.
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26 mm / 1.02 in.
28 mm / 1.10 in.
30 mm / 1.18 in.
Material thickness and notch angle
12.9.5. Tool adjustment
Unique adapter identification
The adapters are recognized by the machine, and the VariAngle unit will have different adjustment values for each adapter.
Unique VariAngle calibration
The VariAngle unit introduces a new calibration; the Notch Angle Calibration . This calibration will automatically run when the cutting table starts. It can also be accessed through the Tool configuration dialog.
Adjustment
Notch Angle Calibration
Lag setting
Tool Height
Tool rotation
Center offset
Notch angle offset
Tool Offset
Description
This is calibrated automatically at first-time use. It can also be recalibrated by wizard.
The nominal value for the Standard adapter is 19 mm / 0.75 in. The optional long adapter for short knife blades has a nominal value of
9.7 mm / 0.38 in.
Note: The Lag setting can be used to adjust overshoot and lead-in of cutting lines.
This is measured automatically. It is possible to add an offset value.
Note: In the Tool Height dialog, you can also specify a notch angle .
This can be used to complete a test cut in the selected angle.
This is for aligning the tool with the moving direction.
This is for aligning the tool with the cutting path.
This is for obtaining the correct notch angle .
This is for aligning tool position with laser pointer or camera.
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An eLearning (English) shows how to adjust the VariAngle unit correctly: https://learning.esko.com/course/view.php?id=56#section-2
For more information about how to run the adjustment wizards, see
on page 64
12.9.6. Basic modes of operation
Note: A material thickness must always be defined when using the VariAngle unit . Select an existing material from the Job window , or create a new material with a thickness from Advanced -> Resources
-> My materials
Opened Job -> Layers Tab -> Edit Layer
Menu Bar -> Layer -> Edit Layer ...
In the Edit Layer dialog, the cutting preferences can be set up.
Notch angle can be set to any angle between 0 and 60 degrees.
New and old terms
• V-notch cut replaces Single Cut
• V-notch Crease replaces Double Cut
• Waste Cut replaces Triple Cut
• Width Offset replaces term "dW"
An eLearning (English) shows how to integrate the correct angle into file workflow and presets: https:// learning.esko.com/course/view.php?
id=23#section-1 .
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The V-notch Cut function will perform an angled cut in the material.
Note that the cut direction of the line is important as it will decide towards where the angled surface is facing.
V-notch Crease will perform two cuts facing each other independent on the specified cut direction. The function is targeted at cutting out a folding trace in the material. Note that the depth setting must be used to define how deep the knife shall cut.
Normally a depth that leaves the bottom liner is specified.
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The illustration above shows typical examples of relation between notch angle and folding angle . The formula to calculate it is:
• Folding angle = 180 degrees – 2 x notch angle .
When the depth of a V-notch Crease is reduced, the distance between the two cuts in the bottom will increase. The Width Offset function can be used to adjust the width of the cut, and thus the space between the two bottom lines in the right picture.
Depending on material properties, it can be dicult to fold the material into the correct folding angle.
Also here the Width Offset function can be used.
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For a 90 degrees folding angle, the nominal recommendation is to decrease the width of the cut by twice the bottom liner thickness. The Width offset function can be used to adjust the width between
-50 to 10 mm / -1.97 to 0.39 in. Example: If your liner is 1 mm / 0.04 in. thick, the Width offset should nominally be -2 mm / -0.08 for a 90 degrees fold. This will depend on the material and potential flute direction. The nominal Width offset values for other angles are added to the VariAngle tooling presets .
They can also be calculated by using the following formula:
• Width offset = (-2) x Liner thickness x Tan( notch angle )
To remove the waste of a V-notch Crease that is still connected to the board, the Waste Cut function can be enables. This function adds a third cut to the line at specified distance from the second cut.
12.9.7. Workflows, set-up and optimization
Please use references and links below for different resources:
• Workflow
• iPC manual, section Optimal Production Workflow .
• Get the best out of iPC, manual (English): Various sections, see Contents.
• eLearning (English): https://learning.esko.com/course/view.php?id=23#section-1 .
• Mapping presets
• iPC manual, section Before we start # Mapping Presets
• Get the best out of iPC, manual (English): Appendix 1 - iPC Resources # Setting up Mapping presets .
• eLearning (English): https://learning.esko.com/course/view.php?id=23#section-1 .
• Tooling presets
• iPC manual, section Before we start # Tooling Presets
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• Get the best out of iPC, manual (English): Appendix 1 - iPC Resources # Setting up Tooling presets .
12.9.8. Advanced operations
To enable these functions, open the Configure Tools dialogue:
Menu Bar -> Advanced -> Configure Tools ...
Reverse operation
If the job has print on the front but should be cut from the back, the Reverse Operation function can be used, see
Job including Reverse Operation on page 44.
Knife Overcut
The Knife Overcut function will add length to the start and/or end of all lines within a layer.
Note that because of the width of the VariAngle blades, there might be a substantial difference between line lengths on top and bottom of the material. By default, the system will expect that the lines in a layer refers to the bottom and will cut the design there. An example is shown below.
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If the VariAngle unit is used as a regular knife tool
(0 degrees cut) to cut out a simple rectangle, the difference between top and bottom might look like the illustration above. Note that if length is added or removed from a line, both sides will be affected.
If the same shape is cut at an angle, e.g. 45 degrees, the difference might look like the illustration above (dashed line refers to opposite side). Note that the lines might not connect to eachother on the top-side. This might make it hard to separate the rectangle from the frame.
Here the Knife Overcut function can be helpful.
For 0 degrees cuts, the “overcuts” can be avoided fully by starting in the corner of each line and cutting towards the middle. In the User manual for iPC , section “10.1.7. Optimize for production”, there are more details about this.
Circle Adjustment
Curved geometries, like circles and arcs, can be cut with the VariAngle unit , both at an angle and when performing regular straight cuts.
Note: Use caution when cutting arcs or circular geometries. If the radius is too small or the boardmaterial too tough, it might cause the blade to break or the knife to cut into the table top. There is no warning for minimum radius, as this will be material and notch angle dependent. It is highly recommended to reduce speed and acceleration when cutting arcs and curves.
To increase the quality of the circular cuts, the Circle Adjustment setting can be used. The setting will change the theoretical lag value of the knife and therefore rotate a little before or after the original setting. This might lead to a cleaner finish, but it could change the radial value of the arc.
Rotational Compensation
Because of the available use cases for the VariAngle unit , the knife blades are quite long. For some materials this will lead to blade flexing. The Rotational compensation function can reduce the flexing of the knife blade by preloading it. This can increase the quality of the cut and in some cases make it easier to cut through challenging materials.
Note: Use caution when applying this function, as too much preloading might cause the knife blade to break or cut into the table top. Further, this setting is only suitable for cutting at an angle, not for 0 degrees cuts.
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The illustrated above shows Rotational Compensation . This will be applied for all lines in the selected layer.
Note: This compensation will only be valid for the given layer and will not affect the angular offset in the Tool configuration menu. The knife blade can be compensated between -3 and 0 degrees.
Multi-pass
Using multi-pass as for milling, can be a good choise for challenging materials, when cutting at an angle. The recommended method is to use two passes. In the first pass cut down to the bottom liner, in the second pass cut through the bottom liner. This can either be done by copying the cutting layers and assigning different cutting depths, or the multi-pass functionality can be used.
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Use the Multi-pass Depth and
Web Thickness settings to do this within a layer.
In the example, the material thickness is 16 mm / 0.63 in. Specifying the full material thickness minus the liner thickness in the Multi-pass Depth field will make the system recognize that it should cut the line in two passes. If you enter the remaining liner thickness into the Web Thickness field, the liner will be cut in the final pass.
Note: If the material is thicker than the total specified in the Multi-pass Depth field and the Web
Thickness field, the machine will perform more than two passes. This is also the case if more depth is added to the cut to get through.
on page 44. More about multi-pass in user manual for iPC.
12.9.9. Work area limitations
Due to the design of the VariAngle unit , the work area of the cutting table will in some cases be reduced. The reduction depends on the table size, notch angle , thickness of the material and cutting direction.
The work area will only be reduced in the red and yellow zones, and only if cutting direction is as indicated with the arrows.The amount of reduced work area depends on the parameters mentioned earlier.
iPC will warn you and not allow start if the Job is outside limits. iPC also tells how much the
Job needs to be moved before it can start. The directions mentioned refer to the table when seen from the front.
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12.9.10. Material lift
If the material is being lifted up from the cutting table during a Job , then the following efforts might help:
• Optimize the Vacuum effect, see
on page 42.
• Increase the amount of material between the outer cut lines and the edges. The amount needed is material dependant, and might also be dependant of the cut direction.
• Ensure that the knife blade is clean. Note: Glue might sometimes stick to it.
12.10.
HPMU
-
High Power Milling Unit
12.10.1. Introduction
Spindle motor
Power rating (max)
Cooling system
Shank size (max)
RPM (max)
Tool change
Vibration sensor board
HPMU chucks
3 kW
Liquid cooling
8 mm
60000
Pneumatic
No
Different chucks are available from http:// www.esko.com/en/store/kongsberg-bits-blades/
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Replacing a chuck
Replacing a chuck is described in detail in Chuck Change and Cleaning on page 126.
This chapter is included just to remind you how important it is to use the Chuck Changing Tool available and a dummy bit to ensure correct mounting:
From left:
Chuck tool, dummy bit with right diameter for the chuck, and chuck.
Chuck change assembly.
Ready to be inserted into the spindle.
12.10.2. Tool Head description
1. Suction House with brush for chip removal.
During normal operation, the house is in down position. When changing bit, the house should be locked in its upper position.
2. Air Blow adjustment. Air Blow is used for milling bit cooling and to ease chip removal.
Adjust for proper operation.
3. Chuck Open/Close . The shown position is closed.
Note: To protect the chuck from damage and the spindle from contamination, do not close the chuck over time without a dummy bit inserted.
Never start the spindle without a bit / dummy bit in the Chuck .
4. Warning Lamp for spindle running.
5. Air Clean Button to help remove contamination.
6. Locking Screw for the suction house.
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1. Milling bit .
2. Chuck . The HPMU is equipped with one 6 mm chuck on delivery.
3. Spindle
HPMU Park Position
A HPMU Park Position is available on the gallows stand.
Use the park position for safe HPMU Tool Head storage.
Note: For safety reasons, always insert a Dummy
Bit when parking.
Chiller / HPMU start up time
Depending upon the environmental temperature, the Chiller needs some start-up time after Power On before it is ready to operate.
Typical delay is 2 – 3 minutes.
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Suction House, adjustable height
On HPMU , you can lock the Suction House in any height; still, it is allowed to move upwards.
This function is useful in order to:
1.
Adapt to different material thicknesses.
2.
Allow false air input in order to reduce suction force.
Procedure:
1.
Loosen lock screw (a).
2.
Adjust suction house to desired height.
Spindle RPM limitations
Running 8 mm bits at a high RPM rate can generate vibrations and excessive wear.
Using Milling Bits with extended length at high RPM can also be dangerous.
Therefore, using long Milling Bits is subject to an automatic RPM reduction.
If you are using short 8 mm bit, these must be limited manually to 40.000 RPM.
In general, 6 mm bits are preferable in materials up to 20–25 mm thickness.
12.10.3. Safety issues
Unattended Operation
Depending upon the material processed, milling introduces some risks.
It is a good rule to keep an eye on a milling job being executed.
Pay special attention to:
• Do not leave the machine running if the vacuum cleaner can be over-filled. This might cause damage, or in worst case a fire if the suction house is clogged.
• Ensure the filter inside the vacuum cleaner is cleaned regulary.
• Be aware the risk of suction tube clogging.
• Be aware the risk of suction house clogging.
• Milling MDF or other fine dust materials requires extra attention in order to keep the vacuum cleaner filter clean.
Vacuum cleaner full
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• Follow the Vacuum Cleaner filling level carefully.
• Empty the container before the level reach the inlet position (indicated in red).
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Suction house
Always, when executing a job, let the suction house float on top of the material.
In addition to chip removal, the suction house reduces the risk of being hit by small work pieces or by a broken milling bit .
Warning : Regularly inspect and clean the suction house to prevent it from clogging. Failing to do so could in worst case result in a fire when a hot milling bit is in contact with the debris.
Ejection of parts
There is a potential risk that personnel can be hit by breaking milling bits or small pieces of processed material. Therefore, eye protection must be used by any personnel working with milling.
• Always use eye protection when working with milling.
Hearing protection
The noise generated by milling varies with the material being processed and running parameters.
Hearing protection is highly recommended and may even be mandatory.
Spindle speed
Never use speeds higher than recommended by the bit supplier. Special care should be taken when using bits with cutting diameter larger than shank diameter.
Milling bits
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Milling bits are very sharp – handle with care.
Milling stop time
The milling spindle does not stop instantly. Always ensure that the red lamp has stopped flashing, and by visual inspection that the milling bit has come to a complete standstill before touching it.
Handling of milling tools
Before dismounting the milling tool from the machine, always replace the milling bit with a dummy bit. A chuck shall never be closed empty, and leaving the milling bit in gives high risk for injury during tool handling.
High temperatures
Be aware, it is normal that the HPMU becomes hot during operation.
Clean surface
Keep the table and material surfaces clean, free from obstacles.
12.10.4. Precautions
Follow these precautions to take care of the milling spindle , which is a high precision unit, that can get damaged by careless use.
Supervision of the milling spindle power
Machine Panel -> Spindle Power
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The HPMU spindle is prepared for continuous operation between 0 – 100 % Watt.
A power load of 70-80% will allow good working conditions for the Spindle Motor .
Too high Spindle Power consumption indicates critical conditions for the motor and immediate actions should be taken:
1.
Use correct and sharp milling bit.
2.
Use correct RPM for the actual bit and material.
3.
Reduce the X/Y speed.
If the motor is running above a critical limit, the execution will stop and a message is displayed.
Use of Non-Balanced Bits
One-flute bits are by nature Non-Balanced , and may destroy the Spindle if used wrong.
Therefore, one-flute bits with cutting diameters above 4 mm, 5/32 inch, must be run with a maximum RPM of 40.000 (HPMU)
Keep distance d small
For best performance and minimum wear, do not let the bit extend out from the chuck more than necessary.
Use bits with short cutting lengths for thin materials.
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Chuck Open/Close valve operation
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Never operate the Chuck Open/Close
Valve while the Spindle is running.
This will destroy the Spindle.
Air Pressure and Quality
Maintain Bit Clamping
Never run IBAG spindle with Pressurized Air disconnected.
This will destroy the Spindle .
Use Clean Air
The Spindle is sensitive for the Pressurized Air quality.
Regularly check the Air Pressure Reduction Valve according to the
.
Un-proper bit clamping may cause the bit to slip in the chuck and damage the Table Top .
1.
Keep the bit shaft clean.
2.
Avoid greasy fingers.
3.
Clean the bit shaft with acetone if necessary, but use only dry cotton tips on the chuck.
4.
Maintain Pressurized Air supply of 7 bar.
5.
Follow procedures strictly: Chuck Change and
Clean .
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Long Term Storage
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More than 4 weeks storage of a Spindle or a HPMU requires:
1.
Turn the Spindle rotor by hand every 4 weeks to reallocate the bearing lubricant.
2.
The Spindle must be stored horizontally.
Remove sharp bit and close the chuck on a dummy bit.
Consider having a Replacement Spindle
If HPMU is used in regular production, it is recommended to have a Replacement Spindle .
The service interval will depend on the type of operation, and is dicult to predict.
Indication of worn bearings may be increasing noise, increasing vibrations or decreasing surface finish.
Note: When replacing a Spindle , torque the motor clamp to 5 Nm, 44 lbf-in using a Torque Wrench .
This is a low torque for that screw size.
Also check by hand that the Spindle rotates smooth without any resistance.
Empty Vacuum Cleaner in time
1.
Do not leave the machine running if the
Vacuum Cleaner can be over-filled. This might cause damage, or in worst case a fire due to the hot milling bit in contact with debris in the suction system.
2.
Be aware the risk of suction house and suction tube clogging.
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12.10.5. Milling advice
Follow this advice for obtaining the best possible milling results.
Milling Bits
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For thin materials, use bits with short cutting length .
For best performance and minimum wear, do not let the bit stick out more than necessary.
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Never use higher RPM than recommended by the bit supplier.
Special care should be taken when using bits with cutting diameter larger than shank diameter .
Bits with small cutting diameter (3-4 mm; 0.12-0.16 in) are more balanced than bits with larger cutting diameter
Thus, they can run with higher RPM, normally 60.000.
Use large diameter bits (5-6 mm; 0.20-0,24 in) when needed only.
Typical use is to get rid of the chips in thick materials.
Max RPM (HPMU) 60.000
Milling bit edges are brittle.
Never let bits touch each other, or other hard surfaces.
Always store in proper container.
Acrylic Bits or Multi Purpose Bits
1. Acrylic Bits (A) are polished, extra sharp for acrylic, wood etc.
2. Multi Purpose Bits (MP) have a higher wear resistance, and are suitable for aluface, plastics, MDF, plywood, wood etc.
Multi Purpose Bits can be identified by a small tooth at the tip (left hand bit on the picture).
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Feed Rates
One-flute Bits do have a good chip flow, and allow for large feed rates. 0.1-0.2 mm/tooth (0.004-0.008 in/tooth) can be a starting point for optimization in most materials:
This gives a feed rate of of 4-8 m/min (2.6-5.2 ips) at
40.000 RPM, and 6-12 m/min (3.9-7.9 ips) at 60.000 RPM.
Light materials, like PVC foam can be run much faster.
The surface finish or the Power Consumption will normally determine the final Feed Rate for an application.
A large drop in RPM, or a high %Watt value in the display, indicate too high Feed Rate .
Large diameter bits require more power than small diameter bits.
Worn bits increase the Power Consumption .
Number of Passes in Thick Materials
The Number of Passes depends on Material Type , Milling Depth and Bit Diameter .
Use a Pass Depth that makes the groove free of chips, normally that is a depth equal to the Milling
Diameter .
Material Hold Down
Material Hold Down may be a limiting factor. Small parts cut loose can be a problem.
This can be done to improve the situation:
1.
Use Milling Bits with smaller Milling diameter .
2.
Cover unused table area to increase Vacuum Hold Down Level .
3.
Use Wash-Out functions instead of creating small waste parts.
Using other tools in combination with the HPMU
It might be necessary to reduce the acceleration in order to achieve an optimal Cutting Quality when combining a heavy tool head with high quality cutting tools.
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12.10.6. Cleaner Device
Kongsberg XP
Cleaning the suction house is simple using a Cleaner Device , which is available as an option.
12.10.7. Bits and Bit Change
How to insert / replace a milling bit
Warning: Sharp tool
1
Ensure the Spindle is not running, and that the red light is off.
Mind the sharp bit, and move the Suction House up.
Lock the house in its up position.
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2
Observe that the milling bit is not rotating, by visual inspection.
Use a cloth to hold the bit.
Move the Chuck Open/Close lever down to open the Chuck .
Put the bit in a proper storage container.
Insert a new milling bit .
Close the Chuck .
3
Only the round part of the shaft should be inside the Chuck .
See the Bit Length and Position – chapter for more
information.
4
Release the Lock to allow the Suction House moving down to its down position.
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5
Regularly, perform a Chuck cleaning, following the dedicated procedure;
on page 126.
Note: Never use Compressed Air for cleaning.
If a Milling Bit is stuck
If a Milling Bit is stuck in the chuck , the probable cause is low air pressure .
To release a Milling Bit from the chuck , a pressure of 7 bar is required.
If necessary, check the Pressurized Air Regulator Valve , or the Pressurized Air source.
If the bit is still stuck, see the Chuck change and cleaning section about how to unscrew the chuck.
12.10.8. Chuck Change and Cleaning
Clean the taper and the chuck regularly for proper operation and optimum life time; at least once a week, but more often if necessary.
Follow the procedure strictly.
Normally, the chuck has a long lifetime.
Extended vibrations or impacts may hurt the chuck , and cause bad milling results.
Trying a new chuck is the easiest way to identify if the chuck is the problem.
Running with a bad chuck will also increase the spindle wear.
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Procedure
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1
Place the Tool Head on the table.
Open the chuck and remove any bit.
Note: Never apply Compressed Air for cleaning.
2
Apply the 17 mm key to hold the Spindle Rotor .
Note: Do not turn the rotor when Chuck is in open position.
This might damage the Spindle .
3
Enter the Chuck Tool with a Dummy Bit into the chuck .
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4
Hold the rotor with the 17 mm key and unscrew the chuck using the Chuck Tool .
If the bit is stuck, hold the rotor with the 17 mm key and unscrew with a 12 mm key.
Note: Tool Open must be pressurized.
5
Use the Taper Brush to clean the Taper .
6
Push the Air Clean Button to help remove contamination.
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7
The Taper Brush must be absolutely free from grease or oil.
If necessary, you must clean it with alcohol before you use it.
This is very important, as it has direct consequence for the clamping force.
8
Apply small quantities of grease to the threads of the chuck , and to the outer cone and cylindric surface of the chuck (green arrows).
Avoid the clamping area (red arrow).
Do not use oil, as it could enter the clamping area and reduce the clamping force.
9
Torque up the chuck by hand, using the Chuck
Tool with a Dummy Bit .
Hold the rotor with the 17 mm key.
10
Close the chuck on a Dummy Bit .
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Chuck Maintenance Kits are available in the Esko
Store on www.esko.com.
12.10.9. Bit Slipping, Chuck Change
Even though the chuck is expected to have a long lifetime, replace it immediately if you experience any problems as:
1.
Bit slipping.
2.
Bit vibrations.
When replacing the chuck , follow instructions in
on page 126.
New chucks are available from Esko store.
12.10.10. Bit Length and Position
Keep distance d small.
For best performance and minimum wear, do not let the bit stick out more than necessary.
Use bits with short cutting lengths for thin materials.
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For proper clamping, keep distance e 20 mm, 0.8
inch, as a minimum.
To achieve material through-cut, the distance d must be at least 18 mm/0.7 inch.
Balanced Bits
Bits with balanced surface should have a clamping length f of min. 20 mm/0.8 inches.
Maximum balancing length g is 12 mm/0.5 inches.
12.10.11. Tool Adjustment
Complete the following adjustments:
Adjustment
Tool Height
Tool Offset
Description
Measured automatically, possible to add an Offset Value .
Adjust offset relative to Laser Pointer .
For more information about how to run the Adjustment Wizards
, see the Tool Configuration chapter
Notes regarding Tool Height adjustment:
When properly adjusted, the milling bit should barely touch the top surface of the material.
12.10.12. Table Top and Tool Height Adjustment
The following rules apply when adjusting HPMU
T = Cutting table
C = Cutting Underlay
Map table top function is carried out on top of the
Cutting Underlay .
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U = Milling Underlay
The Table Top Reference function is carried out on top of the Milling Underlay
The Tool Height is measured automatically.
If, after a test cut, you want to modify the Milling Depth , this is possible from the Tool Height
Adjustment dialog.
The following rules apply when Milling:
Mill on Cutting Underlay (C):
To avoid damage to the Cutting Underlay , the downward movement of the milling bit is stopped
2 mm / 0.08 inch above the cutting underlay.
Thus, it is not possible to mill through the material in this case.
Tool Height will follow the mapped tabletop.
Milling Underlay (U) on top of the Cutting
Underlay :
To be able to mill through the material, the thickness of the Milling Underlay must be > 2 mm /
0.08 inch.
Tool Height will follow the mapped tabletop.
12.10.13. Miscellaneous
Warm Up
Machine Panel Toolbar -> Warm Up
To protect the Spindle , mandatory Warm Up is implemented.
If the Spindle has been inactive for 8 hours or more, a 3 min. Warm Up is required.
If the Spindle has been inactive for 4 weeks or more, an extended sequence is required, called Run In .
This takes 20 minutes.
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Suction House
Clean the Suction House when necessary.
Use acetone and a q-tip.
A smooth surface will ease the chip removal.
Warning : Regularly inspect and clean the suction house to prevent clogging. Failing to do so could in worst case result in a fire when a hot milling bit is in contact with the debris.
Vacuum clean the Milling Underlay
The Vacuum Cleaner can be used for automatic cleaning of the felt mat:
Prepare program to make a file that covers the actual area.
Set “bit size” to 65 mm (2.5 inch).
Hint:
• Make a file name that reflect the size used.
• Prepare Layer Setup with low spindle speed, zero depth, and maximum feed.
• Insert the Dummy Bit into the chuck .
• Adjust the brush height until the brush barely touches the mat surface.
12.10.14. LubriCool (MultiCUT-HP only)
Introduction
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12
LubriCool mounted on HPMU.
• A - inspection window.
• B - Suction cup with nozzles.
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LubriCool control unit
134
How to use
LubriCool is on when the Vacuum Cleaner is on.
For materials where lubrication is not suitable, use the ON/OFF switch on the LubriCool Control Unit to switch off lubrication.
Oil
Use Nozzle Unit or Suction Ring
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Inspection Opening
When the LubriCool unit is on, you can see light in the control relays inside the unit.
For LubriCool, use this oil only:
Accu-Lube LB-5000
Nozzle Unit Suction Ring
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Kongsberg XP is delivered with one Nozzle Unit for the LubriCool function and one Suction Ring with just a brush, and with bigger suction opening.
• Use the Nozzle Unit when the LubriCool function is beneficial only!
• For all other materials, especially MDF, use the Suction Ring !
Note: It is crucial for proper operation that these guidelines are followed.
How to interchange the Nozzle Unit / Suction Ring
Cleaning
Proper cleaning is crucial for correct operation.
• Release locker A and remove the nozzle unit.
• Use vacuum cleaner to clean the HPMU suction house.
• Use vacuum cleaner to clean the nozzle unit.
12.11. Chiller no 1 (blue top) for HPMU
12.11.1. Introduction
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This is chiller 1, replaced in October 2016 by a new model named Chiller 2016.
Flow Measurement
During operation, check the water flow level displayed on the chiller meter.
For proper operation, the flow level should be > 1,0 l/min.
12.11.2. Chiller Heater, Operation
Notes:
1.
The Chiller Heater is optional.
2.
The Chiller Heater must be filled with water before connecting mains.
3.
The Chiller Heater is correctly configured when shipped from the factory. Normally, there is no need for modifications.
Some operating instructions are included here if any modifications are still needed.
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Press On/Off button to start the heater. The letters BCS are displayed. To turn unit off, push and hold the button for 3 seconds.
Media temperature is displayed.
Green light on - the unit is on, and the specified temperature is reached.
Green light flashing - heating elements are operating.
Red light on – fault condition (over-heating, cable breakdown)
Program selection
Press and hold the Menu button for 3 sec.
Use arrow keys to select program
Press Menu button to confirm selection.
Temperature setting
Use arrow keys to select temperature
Press Menu button to confirm selection.
3
4
5
0
1
2
Programs available
Program Temperature range from ( o
C)
10
10
10
Frost protection
10
10
85
70
50
85
50
(
Temperature range to o
C)
Hysteresis
7
4
4
5
7
7
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Program
6
7
Temperature range from ( o
C)
10
10
(
Temperature range to o
C)
85
50
Hysteresis
5
5
Factory Setting
Correct factory setting is Program = 5 and temperature = 26 oC (Chiller with heater).
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12.11.3. Chiller, Error Conditions
One common error signal is routed from the Chiller system to the inverter and further into the control system.
The following error conditions are monitored:
• Temperature out of range (high and low)
• Liquid flow too low (less than 0.5 l/min). The signal is 1 minute delayed.
• Temperature sensor failure
If any chiller failure occurs, you have to look at the chiller display to see the real reason for the problem:
Code
E0
IA
HI
LO
Description
Sensor failure: cable defective, connection failure, sensor defective.
Water level of water flow too low.
Temperature of cooling medium too high
Temperature of cooling medium too low
During normal operation, the cooling medium temperature is displayed.
More information is available from the Operating instructions for the chiller.
12.12. Chiller 2016 / Chiller 2020 for HPMU
12.12.1. Introduction
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Chiller 2016 and Chiller 2020 refers to two similar models introduced those years. Chiller 2020 differs from previous models by being a heat exchanger, which will not be able to lower the temperature below ambient.
Specifications
Dimensions
W x D x H = 480 x 580 x 430 mm / 19 x 23 x 17 in.
(Chiller 2016). W x D x H = 610 x 480 x 450 mm / 24 x
19 x 18 in. (Chiller 2020).
Weight
Empty: 40 kg / 88 lbs. (Chiller 2016)
Empty: 24 kg / 53 lbs. (Chiller 2020)
Filled with liquid: 49 kg / 108 lbs. (Chiller 2016)
Filled with liquid: 33 kg / 73 lbs. (Chiller 2020)
Internal heater
Both these models are equipped with internal, automatic heater.
Chiller Unit
12.12.2. Startup
•
Ensure the following pre-requisites are in place for correct startup:
Note: Never start the chiller without liquid.
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• Signal cable (to inverter) is connected to the chiller unit.
• Chiller fluid level should be MAX. If not, fill with fresh water.
• If water temperature is too low, wait for the temperature to attain proper value ( 19 o
C / 66 o
F ).
The chiller is equipped with an internal, automatic heater.
First time startup
• Check that the supply matches the rated voltage.
• Check that the electrical connection has been made correctly.
12.12.3. Error Conditions
One common error signal is routed from the Chiller system to the inverter and further into the control system.
The following error conditions are monitored:
• Temperature out of range (high and low)
• Water level too low
• Liquid flow too low (less than 0.8 l/min). The signal is 1 minute delayed, to be able to fill water hoses at startup..
During normal operation, the cooling medium temperature is displayed.
If any chiller failure occurs:
• Alarm signal is generated.
• Chiller will stop.
• Look at the chiller display to see the real reason for the problem:
Code
AL
H1 (Chiller 2016)
H1 (Chiller 2020)
L1
Description
Water level or water flow too low. Check for correct water level in the Water
Level Indicator on Chiller front.
Temperature of cooling medium too high, > 35 o
C / 95 o
F
Temperature of cooling medium too high, > 45 o
C / 95 o
F
Temperature of cooling medium too low, < 19 o
C / 66 o
F
Continue after error situation
• Find root cause for the error situation and fix it. Flow too low is normally caused by a squeezed water hose.
• Switch chiller unit OFF and ON again.
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More information is available from the Operating instructions for the chiller.
12.13.
VibraCut
The VibraCut is available in two models:
VibraCut
Kongsberg XP
Running with 6000 RPM and amplitude +/- 0.15 mm (0.006 inches), this tool is recommended for light duty Corrugated Materials .
HF VibraCut (High Frequency VibraCut)
142
Running with 12000 RPM and amplitude +/- 0.6 mm (0.024 inches), this tool is recommended for more demanding Corrugated Materials .
Note: Hearing Protection is recommended when working with this tool.
Common to both models:
• To reduce material tear, a foot is available.
• The same set of Knife Adapters can be used.
Replace Knife Blade
Warning: Sharp tool
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Pull straight out to remove the Knife Foot .
Loosen the screw A and replace the Knife Blade .
Ensure the Knife Blade has correct position relative to the screw.
Push the Knife Blade down while the screw is fixed.
Extreme care should be taken when inserting the
Knife Foot again.
Keep fingers away from Knife Blade as illustrated at left.
Tool Adjustment
For this tool, complete the following adjustments:
Adjustment
Lag Setting
Description
The Knife Lag depends upon the Blade Adapter .
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Adjustment
Tool Height
Tool Rotation
Center Offset
Tool Offset
Description
Nominal value is 0-3 mm.
Measured automatically, possible to add an
Adjust
Adjust
Tool Angle
Tool
tangential to
sideways until centered.
Adjust offset relative to Laser Pointer .
Offset Value
Moving Direction .
.
For more information about how to run the Adjustment Wizards
, see the Tool Configuration chapter
12.14.
Rigid Material Knife
(
RM Knife Tool
)
Replace Knife Blade
Warning: Sharp tool
Use a 3 mm Allen key to fix / loosen the Knife
Blade .
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Ensure the Knife Blade is correctly aligned.
No additional adjustments are necessary, as the tool height is measured automatically.
Tool Adjustment
For this tool, complete the following adjustments:
Adjustments
Lag Setting
Description
The Knife Lag depends upon the Blade Adapter .
Nominal value is 0-4 mm.
Tool Height
Tool Rotation
Center Offset
Tool Offset
Measured automatically, possible to add an Offset Value .
Adjust Tool Angle tangential to Moving Direction .
Adjust Tool sideways until centered.
Adjust offset relative to Laser Pointer .
For more information about how to run the Adjustment Wizards
, see the Tool Configuration chapter
12.15.
HiForce Knife
HiForce Knife is a general purpose knife tool suitable for cutting a wide range of materials.
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As the name indicates; this tool is prepared for a higher tool pressure compared to the Static Knife .
The tool is prepared for a wide range of Knife Blades .
To reduce material tear and also to keep the material down as the Knife Blade is pulled out, a Knife
Foot is available.
Replace Knife Blade
Warning: Sharp tool
Pull straight out to remove the Knife Foot .
Loosen the screw A and replace the Knife Blade .
Ensure the Knife Blade has correct position relative to the screw.
Push the Knife Blade down while the screw is fixed.
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Extreme care should be taken when inserting the
Knife Foot again.
Keep fingers away from Knife Blade as illustrated at left.
Tool Adjustment
For this tool, complete the following adjustments:
Adjustment
Lag Setting
Description
The Knife Lag depends upon the Blade Adapter .
Nominal value is 0-3 mm.
Tool Height
Tool Rotation
Center Offset
Tool Offset
Measured automatically, possible to add an Offset Value .
Adjust Tool Angle tangential to Moving Direction .
Adjust Tool sideways until centered.
Adjust offset relative to Laser Pointer .
For more information about how to run the Adjustment Wizards
, see the Tool Configuration chapter
Replace Knife Adapter
To remove the Knife Adapter , just pull it out from the holder.
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12.16.
Psaligraphy Knife
Note: iPC version 2.0 or higher is required to run this tool.
Psaligraphy Knife is a tool for cutting of fine details in paper and folding carton.
Replace Knife Blade
Warning: Sharp tool
148
For Knife Blade change, remove the foot.
The locking screw will always point towards the cutting direction
Note: Be extremely careful when mounting the foot.
Tool Adjustment
For this tool, complete the following adjustments:
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Adjustment
Lag Setting
Tool Height
Tool Rotation
Center Offset
Tool Offset
Description
The Knife Lag depends upon the Blade Adapter .
Nominal value is 0-3 mm.
Measured automatically, possible to add an
Adjust
Adjust
Tool Angle
Tool
tangential to
sideways until centered.
Adjust offset relative to Laser Pointer .
Offset Value
Moving Direction .
.
For more information about how to run the Adjustment Wizards
, see the Tool Configuration chapter.
12.17.
PressCut
PressCut is a special knife tool for vinyl cutting.
The Cutting Depth is controlled by the downward knife pressure.
The pressure is adjustable from Opened Job -> Edit Layer dialog.
For applications where a more accurate depth control is required, a simple foot solution is available.
The tool is prepared for a wide range of Knife Blades .
Replace Knife Blade
Warning: Sharp tool
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This figure shows how the Knife Blade is fixed inside the PressCut Knife Tool .
The friction between the Alignment Pin A and the
Knife Blade keeps the Knife Blade in place.
A special hand tool is available as an aid when replacing Knife Blades .
Use this hand tool when removing and inserting
Knife Blades into the tool.
When inserting a new Knife Blade , ensure the blade is correctly positioned relative to the
Alignment Pin .
Configure Tools
150
Tool Pressure
PressCut can run with a Constant Tool Pressure or a Speed Dependent Tool Pressure .
Both parameters are specified in the Configure Tools or Opened Job -> Layer structure.
Constant Tool Pressure
In the dialog, specify the Tool Pressure .
The pressure is entered as a gram - value from 40 to 700 grams.
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The Knife Pressure is modified if Speed Dependent Tool Pressure is specified, see below.
During the tool down movement, the knife moves down until the material surface is detected and the proper Knife Pressure is achieved.
The Knife Pressure needed will vary depending upon the material.
For a typical Vinyl Cutting Job , a recommended start parameter is Knife Pressure = 65-70 gram and
Speed Dependent Tool Pressure = 50%.
Note:
For the PressCut to work properly, a sharp Knife Blade is critical.
Pay special attention to the tip of the Knife Blade , as it is easy to break.
Speed Dependent Tool Pressure
In the dialog, specify Ramp and a Ramp Value .
The Ramp Value is entered as a % - value.
The upper curve illustrates the speed of the machine when executing a line.
Curve A illustrates the Knife Pressure if the Speed
Dependent Pressure is set to 0; the pressure is constant from start to stop.
The Knife Pressure level is as specified by the
Knife Pressure parameter, see previous chapter.
Curve B illustrates the Speed Dependent Tool
Pressure .
Ramp Value is set to 100.
When running at full speed, the pressure is the double of the Knife Pressure A.
This function is useful as it allows a lower pressure in both ends of a line where the speed is low at the same time as you get a higher pressure when running at full speed.
Note: The maximum Ramp Value is 200%.
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Foot solution
Kongsberg XP
Normally, the PressCut Knife Tool is used without the foot mounted.
When the foot is mounted, the Cutting Depth d is controlled by the adjustable screw S.
Procedure:
1.
Press clamp C as indicated to lock the Knife
Shaft .
2.
Turn the screw S to adjust the Cutting Depth .
When seen from the Knife Blade side, a clockwise adjustment will increase the Cutting
Depth .
12.18.
RotaCut
152
RotaCut is a special tool for cutting light materials, as thin fabric.
Maximum Cutting Depth is 2 mm / 0.07 inch.
Note: Due to the characteristics of this knife tool, some restrictions apply to the use of it:
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12
• It is not suitable for curves with small diameter.
• It is not suitable for designs containing short lines in combination with sharp angles.
RotaCut is prepared for Decagonal Knife Blades ,
ø25 mm / 1 inch.
How to replace the Knife Blade
Warning: Sharp tool
1
Use the spanner and the hexagonal screw driver to remove the Knife Blade fixing nut.
2
Carefully remove the old Knife Blade and insert the new one.
Ensure the Knife Blade is properly seated.
Mount the nut and fix it properly.
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3
Observe the Guide Pin in the foot and the groove in the Tool Shaft .
Position the foot onto the Tool Shaft as shown at left.
Push the foot into position.
A self-locking mechanism ensures the foot is kept in place.
Note: Be careful not to hit the sharp Knife Blade .
4
Verify by hand that the foot movement is smooth.
154
Tool Adjustment
RotaCut is adjusted in the same way as the other C tools regarding rotation angle and offset.
Tool Height is manually adjusted:
Tool Height for RotaCut is manually adjusted using the tool height adjustment wizard available from the Tool Configuration dialog.
Follow the instructions in the dialog.
Be careful, though, not to adjust the cutting depth too deep into the Cutting Underlay (figure at left).
U - cutting underlay
M - material
D - X/Y moving direction
Layer Setup for RotaCut
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12
Correct setting of Lag - and Width - values are shown.
Lag : 3.5 mm / 0.14 inch
Width : 7.0 mm / 0.28 inch
Use the Lag and Width parameters to achieve proper corner cutting.
12.19.
Braille Tool
1.
Keep the tool in upright position during this process.
2.
Remove the cap and the plunger.
3.
Pour spheres into the tool.
4.
Insert the plunger and the cap. Shake the tool lightly.
5.
Push the dispensing mechanism up.
6.
One sphere should be pushed out from the tool
Plunger
The tool is equipped with a plunger that serves two purposes:
1.
To force the spheres into the internal funnel.
2.
Indicate the number of spheres remaining in the tool. If the groove is no longer visible it means that there is a limited number of spheres left in the tool.
Braille Tool milling bit
The supplied milling bit is heavily unbalanced and should not be run faster than 20.000 RPM to avoid excessive wear to the milling spindle!
This also means that you should not use this bit when warming up the milling spindle as the warm up sequence exceeds 20.000rpm.
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Braille Tool setup
In order to create high quality consistent braille patterns you should perform Tool Height and Tool
Offset calibrations.
Note: It is crucial that the Tool Height is correctly set before running this tool.
The nominal value is Tool Height = Material Thickness .
Meaning, if the material is 6 mm thick, the nominal height setting should be -6 mm (minus 6 mm).
5
6
7
3
4
8
1
2
Tool Offset adjustment
Machine Connection -> Tool Configuration
Load the Braille Tool with black spheres.
Cut a piece of double sided tape measuring approximately 20x20 mm / 0.8x0.8 in.
and stick it to the surface of the working area. Preferably the milling underlay or your selected substrate. It is important that the piece of tape fits within the hole in the measuring foot with good margins.
Insert the Braille Tool in the MultiCUT tool head.
Open up the Tool Adjustment dialog.
Select Braille Tool and press Adjust Active Tool …
Select Tool Offset Adjustment and press Next .
Jog the tool head to the position of the tape so that the laser dot is placed in the middle of the piece of tape.
Press Start . The machine will measure the material thickness and dispense a sphere onto the tape piece.
If the Laser Spot is offset from the sphere, jog the tool head until the Laser Spot is placed exactly on top of the sphere.
10 Click Finish and close the remaining tool adjustment dialogs.
Configure Tool
Menu Bar -> Advanced -> Configure Tools ...
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Braille Tool should be defined with the following parameters enabled:
• Velocity Z (max speed)
• Z-axis Depth (0)
• Drill holes (on)
Preparing Layers for Braille Tool
Opened Job -> Layers -> Edit Layers
When making braille signage, you need two identical Layers with the braille pattern, one for milling holes and one for inserting braille spheres.
These Layers may consist of circles or points.
Layer: Braille Drilling
Velocity Z
Velocity Z is material dependent and may require experimentation.
The value shown in the illustration is suitable for (and has been tested with) 3mm Dibond.
Z-axis depth
Z-axis depth is determined by the material thickness and hole depth.
It can be calculated as: Z-axis depth = hole depth – material thickness.
According to the Raster Braille manual the hole depth should be 1,07mm (0,042”).
You may find that the holes being milled are either too shallow or too deep. If so, use this parameter to adjust to a suitable setting.
You will see this if the spheres sit too low or too high.
The standard specifies a sphere height of 0,6mm (0,023”).
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Example using 3mm Dibond: 1,07mm – 3mm = -1,93mm
Spindle RPM
Spindle RPM is material dependent and may require experimentation. The values shown in the illustration are suitable for 3mm Dibond.
Drill holes
Drill holes check box should be enabled.
Layer: Braille Tool
158
Z-axis Depth
Z-axis depth should initially be set to the material thickness.
This parameter determines the pressure the Braille Tool will use to force the sphere into the hole.
If you are using soft materials and notice indentations in the material, you can lower the value to get a lighter pressure.
On the other hand, if the spheres are not fully inserted into hard materials, like acrylic, you may increase this value to increase the force used by the Braille Tool .
Drill Holes
Drill Holes check box must be enabled for the Braille Tool to work properly.
Creating a Braille Job file
Braille grade 1 & 2
Grade 1 braille is a letter-by-letter translation of texts.
If you wish to create Grade 1 braille signage you can use any available braille font. These fonts may be freely available on the internet.
Grade 2 braille introduces abbreviations and contractions for a large number of commonly used words.
This is the recommended/preferred method of creating braille texts.
For Grade 2 braille you will need dedicated translation software.
Translation software recommendations can be found in the Raster Braille manual supplied with the
Braille Tool .
Operations in the desktop publishing software
To create the Braille patterns select the Braille font and type the text.
Select a font size, which gives correct distance between the dots/patterns. Details are found in the
Raster Braille manual.
As with other fonts, outlines of the text need to be created before creating the output file for i-cut
Vision.
Since the Braille patterns should be drilled with the milling spindle as well as Braille spheres being inserted with the Braille Tool , it is recommended to duplicate the Braille Layer .
Keep other graphics than Braille in separate layers.
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12.20.
CorruSpeed Knife
Note: iPC version 2.0 or higher is required to run this tool.
CorruSpeed Knife tool is made especially for cutting corrugated materials.
Maximum material thickness: 7 mm/0.28 in.
Maximum knife edge height: 6.5
mm/0.26 in; requires minimum 0.5
mm/0.02 in. crush.
During processing, the corrugated material is partly crushed by the foot.
The result is:
• You can run at high speed.
• The risk for material tear is significantly reduced.
Foot pressure adjustment
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Material crushing depends upon two adjustments:
A - Knife tip exposed
Adjust until the distance d is 1.0
mm/0.04 in. less than material thickness.
One turn (CW) on A increase d with 1 mm/0.04 in.
B - Foot pressure
Adjust foot pressure.
C - scale indicating actual pressure.
For optimal performance, the foot pressure must be adapted to each material.
Run some test cuts to find the best combination of knife tip exposure and foot pressure.
Start with foot pressure = 5 and test with different knife tip exposures.
By this, you can find and save settings that are optimal for each type of material.
Note
When adjusting the knife tip exposure, do not adjust the knife tip too far into the foot.
The limit is when the knife tip is flush with the front edge of the foot, or the inner sleeve is flush with the outer sleeve.
Insert Knife Blade
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For Knife Blade change, remove the foot.
• The locking screw will always point towards the cutting direction
• Note: Be extremely careful when mounting the foot.
• Observe the alignment pins.
• After a blade change, the tool depth should be checked again.
12.20.1. Tool adjustment
For this tool, complete the following adjustments:
Parameter
Lag Setting
Tool Height
Tool Rotation
Center Offset
Tool Offset
Description
The knife lag depends upon the blade shape. Normal value is 0 mm.
The tool tip should touch the material surface.
Adjust tool angle tangential to moving direction.
Adjust tool sideways until centered.
Adjust offset relative to Laser Pointer .
For more information about how to run the adjustment wizards, see
.
12.21.
Braille Tool
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Braille Tool, how to add spheres
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Braille Tool will enable you to create signage readable by visually impaired people.
Braille Tool is prepared for use in combination with HPMU .
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1.
Keep the tool in upright position during this process.
2.
Remove the cap and the plunger.
3.
Pour spheres into the tool.
4.
Insert the plunger and the cap. Shake the tool lightly.
5.
Push the dispensing mechanism up.
6.
One sphere should be pushed out from the tool
Plunger
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The tool is equipped with a plunger that serves two purposes:
1.
To force the spheres into the internal funnel.
2.
Indicate the number of spheres remaining in the tool. If the groove is no longer visible it means that there is a limited number of spheres left in the tool.
Braille Tool milling bit
The supplied milling bit is heavily unbalanced and should not be run faster than 20.000 RPM to avoid excessive wear to the milling spindle!
This also means that you should not use this bit when warming up the milling spindle as the warm up sequence exceeds 20.000rpm.
Braille Tool setup
In order to create high quality consistent braille patterns you should perform Tool Height and Tool
Offset calibrations.
Before adjusting offset you should set the tool height of the Braille Tool . This can be done manually or automatically using X-Pad .
Note: It is crucial that the Tool Height is correctly set before running this tool.
The nominal value is Tool Height = Material Thickness .
Meaning, if the material is 6 mm thick, the nominal height setting should be -6 mm (minus 6 mm).
1
2
Tool Offset adjustment
Machine Connection -> Tool Configuration
Load the Braille Tool with black spheres.
Cut a piece of double sided tape measuring approximately 20x20 mm / 0.8x0.8 in.
and stick it to the surface of the working area. Preferably the milling underlay or your
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3
4
5
6
7
8
Kongsberg XP selected substrate. It is important that the piece of tape fits within the hole in the measuring foot with good margins.
Insert the Braille Tool in the HPMU tool head.
Open up the Tool Adjustment dialog.
Select Braille Tool and press Adjust Active Tool …
Select Tool Offset Adjustment and press Next .
Jog the tool head to the position of the tape so that the laser dot is placed in the middle of the piece of tape.
Press Start . The machine will measure the material thickness and dispense a sphere onto the tape piece.
If the Laser Spot is offset from the sphere, jog the tool head until the Laser Spot is placed exactly on top of the sphere.
10 Click Finish and close the remaining tool adjustment dialogs.
Configure Tool
Menu Bar -> Advanced -> Configure Tools ...
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Braille Tool should be defined with the following parameters enabled:
• Velocity Z (max speed)
• Z-axis Depth (0)
• Drill holes (on)
Preparing Layers for Braille Tool
Opened Job -> Layers -> Edit Layers
When making braille signage, you need two identical Layers with the braille pattern, one for milling holes and one for inserting braille spheres.
These Layers may consist of circles or points.
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Layer: Braille Drilling (HPMU)
Velocity Z
Velocity Z is material dependent and may require experimentation.
The value shown in the illustration is suitable for (and has been tested with) 3mm Dibond.
Z-axis depth
Z-axis depth is determined by the material thickness and hole depth.
It can be calculated as: Z-axis depth = hole depth – material thickness.
According to the Raster Braille manual the hole depth should be 1,07mm (0,042”).
You may find that the holes being milled are either too shallow or too deep. If so, use this parameter to adjust to a suitable setting.
You will see this if the spheres sit too low or too high.
The standard specifies a sphere height of 0,6mm (0,023”).
Example using 3mm Dibond: 1,07mm – 3mm = -1,93mm
Spindle RPM
Spindle RPM is material dependent and may require experimentation. The values shown in the illustration are suitable for 3mm Dibond.
Drill holes
Drill holes check box should be enabled.
Layer: Braille Tool
Z-axis Depth
Z-axis depth should initially be set to the material thickness.
This parameter determines the pressure the Braille Tool will use to force the sphere into the hole.
If you are using soft materials and notice indentations in the material, you can lower the value to get a lighter pressure.
On the other hand, if the spheres are not fully inserted into hard materials, like acrylic, you may increase this value to increase the force used by the Braille Tool .
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Drill Holes
Drill Holes check box must be enabled for the Braille Tool to work properly.
Creating a Braille Job file
Braille grade 1 & 2
Grade 1 braille is a letter-by-letter translation of texts.
If you wish to create Grade 1 braille signage you can use any available braille font. These fonts may be freely available on the internet.
Grade 2 braille introduces abbreviations and contractions for a large number of commonly used words.
This is the recommended/preferred method of creating braille texts.
For Grade 2 braille you will need dedicated translation software.
Translation software recommendations can be found in the Raster Braille manual supplied with the
Braille Tool .
Operations in the desktop publishing software
To create the Braille patterns select the Braille font and type the text.
Select a font size, which gives correct distance between the dots/patterns. Details are found in the
Raster Braille manual.
As with other fonts, outlines of the text need to be created before creating the output file for i-cut
Vision.
Since the Braille patterns should be drilled with the HPMU spindle as well as Braille spheres being inserted with the Braille Tool , it is recommended to duplicate the Braille Layer .
Keep other graphics than Braille in separate layers.
12.22.
Drill / Pen Tool
Tool Insert Position
If included, the Tool Insert Position is permanently mounted on the P1 - tool position.
The holder is prepared for Ballpoint Pen , Drill Tool or Ink Tool .
Note: Tools for the Tool Insert Position can not be used in combination with HDU (Heavy Duty Unit),
Foam Knife and HPMU (High Power Milling Unit).
How to insert / remove a drill / pen tool
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Inserting a tool - push down until the
Tool is locked in position.
To remove a Tool - press the Release
Button .
Pen/Drill Motor Connector :
To release, grab the housing and lift straight up.
To insert, move connector carefully down and turn it until it fits.
Then just push the connector down until it is locked in position.
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12.23.
Drill Tool
Kongsberg XP
This Drill Tool is for use in re-board and other paper - based materials.
The Tool is prepared for drill bits 0.5 – 6 mm (0.02 - 0.24 inches).
How to replace a Drill Bit
Push the Drill Bit towards the bottom of the chuck.
Use the wrench to fix the bit in the chuck.
No additional adjustments are necessary, as the tool height is measured automatically.
Tool Adjustment
For this Tool , complete the following adjustments:
Adjustment
Tool Height
Tool Offset
Description
Measured automatically, possible to add an Offset Value .
Adjust offset relative to Laser Pointer .
For more information about how to run the Adjustment Wizards
, see the Tool Configuration chapter
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12.24.
Ballpoint Pen
Ballpoint Pen is available for pen drawing.
Tool pressure is adjustable by a knob on top of the tool.
Tool Assembly and Pressure Adjustment
A - Inner sleeve.
The Ballpoint Pen refill is fixed inside the sleeve using a screw.
Use Allen Key , 3 mm.
B - Sleeve holder with spring and Pressure
Adjustment Knob .
C - pen tool
Adjust Tool Pressure using the screw s.
Lock the adjustment screw using the locking knob k.
Tool Adjustment
For this tool, complete the following adjustments:
Adjustment
Tool Height
Center Offset
Tool Offset
Description
Measured automatically, possible to add an offset value.
Adjust tool sideways until centered.
Adjust offset relative to laser pointer.
For more information about how to run the Adjustment Wizards
, see the Tool Configuration chapter
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12.25.
Measuring Foot
Kongsberg XP
The Measuring Foot (M) has 3 functions:
1.
Measure the thickness of the material on the table
2. Map Table Top Surface .
3.
Calibration of the Measuring Station . No adjustments are necessary.
12.26.
Laser Pointer
The Laser Pointer (L in the illustration) is a Class II laser beam Pointing Device .
Wavelength: 650 nm, 1 mW.
The Laser Pointer is used in adjustment wizards and job execution to indicate current position on the table.
The Laser Pointer is lit as long as it indicates the correct current position.
If there is no manual operation of the table, the Laser Pointer will be switched off after a 30 sec. time out.
Pressing any button on the Operator Panel will switch the Laser Pointer on again.
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13. Maintenance
13.1. General
Warning
The Main Power should be switched off before cleaning is carried out.
More detailed information about C system maintenance is available in the
Maintenance Manual .
13.2.
Daily Maintenance
Inspect
• Inspect the equipment in order to prevent any irregularities.
Clean
• The Table Surface should be kept clean at all times. For cleaning, use iso-propyl alcohol or white-spirit.
• The room should be cleaned regularly. Keep the cables free from grease, floor vax etc.
• Use a Vacuum Cleaner to keep the inside of the Conveyor belt clean.
• Inspect and clean if necessary the inside of the milling suction house.
13.3.
Weekly Maintenance
Guide-ways and Bearings
The guide-ways and the bearings should be thoroughly cleaned and oiled very lightly with Tellus R10 oil.
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Photo Cells
The surface of the Transmitter and Receiver should be carefully cleaned using light soap and clean water.
Air Pressure Reduction Valve
The automatic draining action of the Air Pressure Reduction Valve should be controlled:
1.
Switch off the Air Compressor and allow the air pressure to fall.
2.
Switch on the Air Compressor and check that any water in the glass bowl of the pressure reduction valve drains out automatically during the first few seconds of operation.
3.
Remove and clean the bowl if the automatic draining action does not operate or if it appears to be an excessive amount of dust in the bowl.
Warning
If the automatic draining action fails, water can enter the Tool Assembly resulting in severe damage.
13.4. Monthly Maintenance
Warning!
The Main Power should be switched off before any maintenance is carried out
Monthly maintenance includes:
Gears
Gears should be re-greased using the grease gun.
The grease nipples are available through holes in the covers; it is not necessary to remove any cover in order to complete this maintenance.
Apply grease to gear wheels:
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X1 axis gear:
X2 axis gear:
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As grease is applied through the extension tube and onto the gear wheel, it is important that the grease is distributed around the wheel.
• In one spot, apply just a small amount of grease (one push).
• Move the traverse or carriage a little in order to turn the gear wheel.
Repeat this procedure 5 times on each wheel.
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Y axis gear:
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Racks
The racks in X1, X2 and Y should be re-greased:
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X1 (above) X2 (above)
Procedure
Y (above)
Use the soft brush to apply grease to the racks.
No covers have to be removed to complete this procedure.
Apply small dots of grease every 25 cm /
10 inch along the entire length of the rack, on X1 and X2 side.
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Repeat the procedure for Y – along the traverse.
Conveyor belt with tension control (option)
Check belt tension by the indicators on both sides.
If the green mark is outside the range of the line, the conveyor should be checked by a trained technician.
Check the conveyor Y position on the rollers front and rear. The conveyor edge should be close to the middle, short line as shown. If this is not the case, the conveyor should be checked by a trained technician.
On lower rear roller, there are pneumatic mechanisms for auto-correction of the conveyor position. These will slightly move the roller in and out to corrigate the belt position.
Observe the system in regular production.
• If this movement is frequent, i.e. more often than once per five full feeds of the conveyor, the system should be checked by a trained technician.
• If there is movement on both sides, the system should also be checked.
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By activating the sensors by hand, the function of the system can be verified.
Vacuum Table (no conveyor)
Every other month, or after the table surface has been cleaned, the closed vacuum holes in the surface should be opened in order to retain the hold-down eciency.
Use a steel pin, 0.5 - 0.6 mm.
While the vacuum system switched on, free the vacuum holes by pushing the obstructions down into the table.
13.5. Maintenance, External Equipment
All external equipment, as PC, Vacuum pump and compressor should be maintained according to the
User Manual for the actual equipment.
13.6. Maintenance, Take Up Unit
13.6.1. General
There is no specific need for a maintenance interval for the TakeUp Unit .
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It is recommended to check the foam rubber on the Waste Handling kit daily for damage and if it is worn out.
13.6.2. Spare Parts
Spare parts available:
Part no
42468512
42468520
42468538
42468546
42468553
42468561
42468579
Description
TAKEUP_GASSPRING
TAKEUP_GASSPRING GUIDING ROLLER
TAKEUP_ TOP GUIDING ROLLER
TAKEUP_POTENTIOMETER DANCERROLL
TAKEUP_RUBBERCORD Ø11MM
TAKEUP_ COVER BEARING BLOCK
TAKEUP_ SWITCH EMERGENCY STOP
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14. Fuse Replacement
Before starting the Fuse Replacement procedure:
• Switch Power Off using the Main Power Switch
• Remove the Main Power plug from the wall socket
Note: Some equipment described might be optional.
14.1. MPU fuses
MPU Location
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Note: MPU location is model dependent.
All fuses are located on the rear side of the Main Power Unit (MPU).
Fuse Location
Procedure
1.
Remove base cover in front of MPU
2.
Remove one fuse and check with ohm-meter. If blown, replace with a new identical fuse.
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3.
Repeat for each fuse.
4.
Replace base cover
5.
Insert main power cable into the wall socket and turn main power on.
Fuse Details
All fuses are: 1 1/4 x 1/4 in (6,3 x 32 mm)
Fuse location
Line fuses F1 and F2
200V Servo power fuse F200
48V Servo power fuse F48
+24V fuse F4
115V
T 15A 250V
T 15A 250V
T 8A 250V
T 6.25A 250V
230V
T 6,25A 250V
T 15A 250V
T 8A 250V
T 6.25A 250V
14.2. X1
X1 Amplifier Location
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Fuse Location
1 – 8/24A AC amplifier X1
2 – SCU unit
Procedure
1.
Remove X1 cover.
2.
Remove cover from AC amplifier unit.
3.
Check fuses F2 – F5 with ohm - meter. If blown, replace with a new identical fuse.
4.
Replace covers.
5.
Insert main power cable into the wall socket and turn main power ON.
Fuse Details
T 10A 250V (5 X 20 mm).
14.3. X2
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X2 Amplifier Location
Fuse Location
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Procedure
1.
Remove X2 cover.
2.
Remove cover from AC amplifier unit.
3.
Check fuses F2 – F5 with ohm - meter. If blown, replace with a new identical fuse.
4.
Replace covers.
5.
Insert main power cable into the wall socket and turn main power ON.
Fuse Details
T 10A 250V (5 X 20 mm).
14.4. Y
Y Amplifier Location
Fuse Location
1 – Y-motor with encoder.
2 – TCU.
3 – AC amplifier for Y.
4 – Z1 – motor.
5 – Z2 – motor
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Procedure
1.
Remove Y cover.
2.
Remove cover from AC amplifier unit.
3.
Check fuses F2 – F5 with ohm - meter. If blown, replace with a new identical fuse.
4.
Replace covers.
5.
Insert main power cable into the wall socket and turn main power ON.
Fuse Details
T 10A 250V (5 X 20 mm).
14.5. P1/P2 fuses
P1/P2 Amplifier Location
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Fuse Location
1 – Y-motor with encoder.
2 – TCU.
3 – AC amplifier for Y.
4 – P1 – motor.
5 – P2 – motor
Procedure
1.
Remove Y cover.
2.
On the TCU – unit, check fuses Fz1 and Fz2 with ohm - meter. If blown, replace with a new identical fuse.
3.
Replace covers.
4.
Insert main power cable into the wall socket and turn main power ON.
Fuse Details
T 4A 250V 1 1/4 x 1/4 in (6,3 x 32 mm).
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14.6. Fuses on various tools
Tool Board location
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Fuse location:
Fhr - Tool rotation fuse.
Fu/d - Tool up/down or tool reciprocation fuse.
Procedure:
1.
Fuses are available on the Tool Board inside the actual tool.
2.
Remove the plastic cover on the tool.
3.
Remove fuse Fhr or Fu/d as illustrated above
(lift straight up).
4.
Check with ohm - meter. If blown, replace with a new identical fuse.
5.
Insert main power cable into the wall socket and turn main power ON
6.
For information about fuse sizes, see table below.
Fuse Details
Tool Head Function
Drill Tool
HF VibraCut Knife
Tool
Drill
Hiforce Knife Tool Tool Rotation
HF VibraCut Knife
Tool
Tool Rotation
Vibration
Fuse Fuse
Size
Fuse Type
Fhr 2 T 2A 125V NANO (42441618)
Fhr 2 T 2A 125V NANO (42441618)
Fhr 2 T 2A 125V NANO (42441618)
Fu/d 4 T 4A 125V NANO (42444828)
Tool Head Function Fuse Fuse
Size
Fuse Type
Presscut Knife Tool Tool Rotation
Presscut Knife Tool Tool u/d
RM Knife Tool Tool Rotation
RotaCut Knife RPM
VariCut Knife Tool Tool Rotation
Fhr 2 T 2A 125V NANO (42441618)
Fu/d 0.75 T 0,75A 125V NANO (42442541)
Fhr 4 T 4A 125V NANO (42444828)
2 T 2A 125V NANO (42441618)
Fhr 2 T 2A 125V NANO (42441618)
VariCut Knife Tool Knife Depth
VibraCut Knife Tool Tool Rotation
VibraCut Knife Tool Vibration
HDU (XP) Tool Rotation
Dual HDU
Dual HDU
VariAngle unit
VariAngle unit
Tool Rotation
Tool Up/down
Fu/d 0.5 T 0,5A 125V NANO (42441600)
Fhr
Fu/d
Fhr
Fhr
2
2
4
4
T 2A 125V NANO (42441618)
T 2A 125V NANO (42441618)
T 4A 125V NANO (42444828)
T 4A 125V Nano
Fu/d 0.5 T 0.5A 125V Nano
Tool rotation Fhr 4 T 4A 125V NANO (42444828)
Tool angle up/down Fu/d 1 T 1A 125V NANO (42477091)
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14.7. Chiller fuse, Hyfra (blue top)
Remove the on/off button Remove cover (4 screws)
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Fuse location Pull out the fuse holder
Kongsberg XP
Turn the fuse holder 90 deg.
14.8. Heater for Chiller Fuse
Heater Fuse Location
Now you have easy access to the fuse.
1 - Spare fuse
2 - Fuse in action
Fuse when mains 115V: T 2A 250V (5x20 mm)
(42424150)
Fuse when mains 230V: T 1A 250V (5x20 mm)
(42468058)
The Fuse is available inside the connector cover.
Fuse details
F - 4A 250V T 5x20mm Slow Blow (42448944)
14.9. Chiller 2016 / Chiller 2020 Fuse replacement
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Fuses are located on the PCB inside the Chiller unit.
Each fuse is protected by a cover as shown upper right.
Lift straight up to remove.
Fuses when 115 V:
F1 - T 16A 250V (5 X 20 mm) (42468066)
F2 - T 16A 250V (5 X 20 mm) (42468066)
F3 - T 500 mA 250V (5 X 20 mm) (42468074)
Fuses when 230 V:
F1 - T 12A 250V (5 X 20 mm) (42468082)
F2 - T 12A 250V (5 X 20 mm) (42468082)
F3 - T 500 mA 250V (5 X 20 mm) (42468074)
14.10. Sound Insulating Box, Circuit Breaker for fan
A separate circuit breaker for the fan is introduced.
A
For proper operation, ensure the ON/OFF switch A is in ON position.
B
Correct fuse setting for the fan is B = 1.0 A.
When the Circuit Breaker is triggered
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The ON/OFF switch is in a middle position.
• Find and remove the root cause for the problem.
• Set the ON/OFF switch A to ON.
14.11. TakeUp Unit, Fuse replacement
The fuses are mounted on the main electrical mounting plate behind the sheet metal cover on the right side of the machine.
Fuse F1:
T10 A, 250V, 5x20mm (42448985)
The same fuse size is used regardless 115V/230V.
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Fuse F2:
T2.5 A, 250V, 5x20mm (44347540)
The same fuse size is used regardless 115V/230V.
14.12. Motorized Roll Feeder, Fuse replacement
The fuses are mounted on the main electrical mounting plate behind the sheet metal cover on the right side of the machine.
The same fuse sizes are used for 115 V as well as 230 V.
Spare fuses are found in each fuse holder as well as in the accessory kit.
Fuse 10F1 :
T10 A, 250 V, 5x20 mm (42448985)
Fuse 10F3 :
T3.15 A, 250 V, 5x20 mm (42476168)
Fuse 15F1 :
T100 mA, 250 V, 5x20 mm (42476184)
Fuse 15F2 :
T5 A, 250 V, 5x20 mm (42448951)
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15. Roll Feeder
A – Bracket Position Pin (push the center button to release the lock).
B – Roll Holder Bracket .
C – Brake Position Locker .
D – Roller Brake .
E – Brake Tension adjustment. Turn clockwise to increase tension.
To adapt to different roll sizes, three Roll Holder
Positions are prepared.
To move the roller bracket, remove pin (A) and release locker (C).
To disengage the Roller Brake , release the Brake
Position Locker (C) and tilt the bracket.
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16. Collector Basket
Kongsberg XP
The unit is placed in the unload end of the conveyor belt (front of table).
The unit is prepared for rigid pieces up till 200x200 mm / 8x8 in, or flexible materials.
Maximum load weight is 30 kg / 65 lbs.
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17. TakeUp Unit
17.1. Introduction
Scope
This manual refers to the TakeUp Unit
The manual contains useful and important information for proper functioning and maintenance of the machine.
It also contains important instructions to prevent accidents and serious damage prior to and during operation of the machine, and it enables the product to perform as safely and flawlessly as possible.
• Read this manual carefully before starting the machine.
• Familiarize yourself thoroughly with the functioning of the machine
• Strictly observe the directions given.
Liability
The data published in this manual are based on the latest information available.
They are subject to future modification.
We reserve the right to change the construction and/or design of our product, without being obliged to adapt earlier supplies accordingly.
Warranty
The warranty conditions stated in our terms of delivery, which are in your possession, are applicable to this product.
The warranty on your equipment become null and void if:
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• Service and maintenance are not carried out strictly in accordance with the instructions, repair work is not carried out by our personnel or has been performed without prior written consent.
• The TakeUp Unit is modified without prior written consent; non-original parts are used.
• The equipment is used inexpertly, incorrectly, carelessly or not accordance with its nature or intended use.
Wearing parts are not covered by the warranty
Safety
Familiarize yourself with the pictograms.
The equipment is provided with safety and protection features.
Even so, caution is necessary when performing machine operations.
Warning pictograms in the various sections point to potential dangers. You will find these pictograms near the text referring to the operations risks.
Work safely!
We have made everly effort to inform you as correctly and completely as possible on any dangers associated with the operation of the machine.
You must ensure and are responsible for compliance with these behavioural guidelines.
The buyer/user is obliged to familiarize operating, cleaning and maintenance personnel with these instructions .
17.2. Machine Description
The TakeUp Unit is a machine specially developed to take-up media, with minimum pull on the media.
Frame
The frame of the TakeUp Unit consists out of two metal frame plates which are connected to each other by a folded plate.
The main electrical components are mounted on the left frame plate.
The left and right side of the TakeUp Unit are protected with metal cover plates which are mounted to the frame plates. Other machine sub-assemblies are mounted in between the both metal frame plates
Operation
There is one switch on the left top-side of the TakeUp Unit .
This switch switches the machine on and off.
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The emergency stop on the top of both sides of the TakeUp Unit can be used to stop the machine immediately.
The dancer roller controls the turning direction of the TakeUp Unit .
When there is new media provided to the TakeUp Unit by for example a cutting table, the dancer roller will follow the media and lowers in the machine.
When the dancer roller lowers in the TakeUp Unit , the machine will start winding the material till the dancer roller rises to his neutral zone.
Winding shaft
The TakeUp Unit is equipped with a Autogrip shaft, which is driven on the left side of the machine.
This autogrip shaft has a variable winding speed depending on the height of the dancer roller.
Machine Identification
The TakeUp Unit has an identification label, a typical label is shown in the picture.
The identification label is positioned on the left side of the machine, where the power cable is entering the machine.
17.3. Safety
General
The TakeUp Unit has safety equipment to promote safe machine operation, see next chapter.
You must, however, take note of the following:
Make sure that clothing, long hair etc. are not caught by rotating rollers, which would involve the risk of being trapped.
Emergency stop button:
The Emergency Stop buttons are positioned on top of the safety covers at the TakeUp Unit .
Press the Emergency Stop button to stop all rotating parts at once.
Pictograms
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DANGER: VOLTAGE
Only qualified personell is authorised to open these parts of the machine to perform maintenance operations.
In this case, ensure that the power is turned off.
Do not remove or open the left metal safety covers of the machine, you may get injured by voltage or rotating parts.
Open or remove the covers only to carry out maintenance. In this case, ensure that the machine is powered down.
Do not place heavy objects on the power supply cord.
Do not place objects on the covers.
The machine has two emergency stop buttons which may be pressed in dangerous situations.
Pressing one of the emergency stop buttons will immediately result in halting of the moving and rotating parts.
Obligations of the Owner
The owner of the machine has to make sure that the only people allowed to work with and on the machine have understood the basic rules on workplace safety and accident prevention.
The owner will make sure that the personnel is trained in the handling of the machine and have been familiarized with the operating and safety instructions contained within this manual.
The safety awareness of personnel shall be reviewed at regular intervals.
Obligations of the Personnel
All individuals working with and on the machine commit to be familiar with the basic regulations on industrial safety and accident prevention and the section on safety contained within this manual.
Dangers caused by Operation of the Machine
The TakeUp Unit is built according to accepted engineering standards and safety regulations.
Despite that, operating the machine could result in danger for life and limb of the operator or cause damage to the equipment or other property.
The machine shall be used only:
• For the intended use.
• In absolutely perfect condition.
Malfunctions or damage that may affect the safety must be serviced immediately.
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Intended Use
The TakeUp Unit is only intended to be used for winding up media.
Any different or additional use of the machine is considered improper and Esko is not responsible for any resulting damage to machine or individuals.
Intended use does include:
• Following all instructions in this manual.
• Carrying out inspection and maintenance operations.
Safety Features
• Before start-up of the machine, make sure that all safety features are properly installed and operational.
• Safety covers may only be removed and replaced when the machine is at a complete stop and powered down.
Informal Safety Measures
• The user manual must be kept with the machine.
• In addition to the operating instruction, the local accident prevention regulations and environmental regulations should be available.
• All safety instructions and warning pictograms must remain in legible condition.
Security Measures for Normal Operation
• Only operate the machine if all safety features are fully functional.
• Before start-up of the machine, ensure that no other individuals are to be at risk.
• Check the machine for obvious damage and the safety features being functional at least once every shift.
• Only operate the machine if all gauges and warning lights are fully functional.
Dangers Caused by Electricity
Maintenance on the electrical system should only be carried out by qualified mechanics
17.4. Features and components
Components overview
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17.5. General operation
Control positions
A - Emergency switch
B - Autogrip shaft
C - Dancer roller
D - Frame
E - Control panel
D - Waste handling kit
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The TakeUp Unit is normally operated from the right side of the machine.
Controls
At the left side of the frame are the operating switches.
These switches allow the operator to control the power (on or off), the turning direction, the winding speed and the possibility to jog the machine.
The different controls are shown in picture:
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A - Jog forward/backward
The jog button turns the autogrip shaft slowly forwards or backwards.
To Jog, the winding direction button has to be set in position: 0.
B - Winding direction
The winding direction button controls the winding direction of the TakeUp Unit .
C - Winding speed
The windig speed potentiometer controls the winding speed.
D - Spare
E - Power button
The power button switches the machine on or off.
F - Control lamp
The control lamps indicates if the machine is turned on or off.
17.6. Applying Winding Material
Applying winding material to the Autogrip shaft
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Infeed loop
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Add a 3 in. coil on the Autogrip shaft.
Bring the material with the Kongsberg table to the TakeUp Unit till the material is fed far enough underneath the waste handling kit to reach the
Autogrip shaft.
Take the winding material underneath the dancer roller and paste it with tape in a straight line onto the coil.
See picture for the typical loop of the winding media.
Avoid angular tension in the media; the media will start telescoping during the winding.
Note: TakeUp Unit should be started only when material is in place.
Aligning the media on the Autogrip shaft
17.7. Start the
TakeUp Unit
The TakeUp Unit is activated for processing when:
• The power button is switched on.
• The Emergency Stop button is pulled up (in de-activated position).
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The TakeUp Unit is activated.
The machine starts processing.
It stops when the dancer roller is in neutral position, the power button is switched off or when the emergency stop is activated.
Attention:
The TakeUp Unit does not stop automaticly when the waste roll is full.
This has to be done manually by switching off the power button or by activating the emergency stop button.
17.8. Using the Autogrip Shaft
Put the core/media roll central on the autogrip shaft, which uses rubber blocking cords to grip with.
Rotate the core/media roll to engage it with the autogrip-shaft.
Note: If a core/media roll of the same size is often used; install a roll clamp at one side of the shaft, to enable easy replacement.
Autogrip shaft installation
The shaft is hung in a special T-slot on one side of the machine and a suspension point on the other side.
The suspension points on both sides of the
TakeUp Unit are provided with a locking ring to prevent the Autogrip shaft from falling out.
The locking ring has to be turned manually to locked or unlocked position.
T-slot of TakeUp Unit
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Attention:
During operation, the locking rings need to be in locked position, to ensure safe operation and avoid risks for the operator.
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Locking ring in unlocked position Locking ring in locked position
Exchange media rollers
The media needs to be cut when the media roll has reached it’s maximum diameter or when the roll has to be exchanged.
Before cutting the media, the TakeUp Unit has to be always switched off.
The tip has to be stuck to the roll to prevent unwinding during transportation.
The TakeUp Unit is provided with a jog button to get an easy exchange of the rollers.
This makes is possible to rotate the roller contrary by hand to get the T-slot in position to exchange the media roll.
Attention:
When removing the Autogrip shaft.
Always lift the side of the Autogrip shaft near the control panel of the TakeUp
Unit first, to avoid damage to the T-slot.
Dancer roller
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The dancer roller (D) in the TakeUp Unit controls the winding of the media.
When the dancer roller lowers the winding unit will start winding, till the dancer roller rises to the start position.
Resetting TakeUp Unit
The dancer roller will move to its lowest position when a roll of material is completed.
The TakeUp Unit will shut-off automatically, when the dancer is longer then 4 seconds in the bottom position.
The full roller can now be replaced by a new, empty core.
The TakeUp Unit can be restarted by switching the winding direction to “0”, and then back to a winding direction.
The TakeUp Unit will now start winding, till the dancer roller rises to the neutral position.
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18. MRF Quick start guide
1.
Make sure the Automatic winding direction switch (A) is switched off.
2.
Release Autogrip shaft a.
Turn the shaft so the triangular warning sticker is facing up b.
Push open the Safety chuck
3.
Load new roll a.
Add core on the shaft – Centered b.
Place the Auto grip shaft back in the fixture c.
Close the Safety chuck
4.
Center the shaft using Edge Control Centering button (E)
5.
Make sure the dancer is in upper loading position
6.
Load material in loop a.
Unwind enough material to feed the loop - using Manual Jog (D) b.
Push the material under the dancer bar and on to the table
7.
Lower the feeder paws/bar with foot pedal.
8.
Unlock the dancer by pulling and turn the looking bolt.
9.
Manually lower the dancer and check feeding direction - Using Manual Jog (D)
10.
Enable Automatic Winding direction switch (A) in the same direction.
11.
Adjust tension weights if needed
12.
Feed first table using manual feed on the Cutting Table
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19. MRF Weight list
Material
For commonly used materials, print out and fill in this list.
Number Material Number
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20. Vacuum Cleaner
20.1. Vacuum Cleaner, Zefiro
20.1.1. How to use
Filter Shaking
Filter Shaking is important in order to maintain a good Vacuum Cleaner performance.
Filter Shaking is best operated every time before use and after prolonged operation.
Note: This operation must be performed only when the Vacuum Cleaner is switched off and the motor has stopped.
Remove Material Container
1
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2
3
Note: You can use the container with or without Plastic Bag .
Use Plastic Bag in Material Container
Parts needed: Steel ring and plastic bag Fix the Plastic Bag to the ring in this way
Ring and Plastic Bag ready for the container Fold/fix the Plastic Bag around the container
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Container with Plastic Bag ready for operation
Detailed information about how to operate the Vacuum Cleaner is available in the Zefiro 75 Operators and maintenance manual.
20.2. Vacuum Cleaner, High-capacity, TB ESKO
20.2.1. How to use
Introduction
1 – Filter Chamber
2 – Filter Shaking Lever
3 – Removable Material Container
Note:
Carefully observe the Vacuum Cleaner filling level.
If the Vacuum Cleaner container is filled up completely, the dust removal function will stop with a high risk for Spindle Motor damage.
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Filter Shaking
Remove Material Container
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Filter Shaking is important in order to maintain a good Vacuum Cleaner performance.
Filter Shaking is best operated every time before use and after prolonged operation.
Note: This operation must be performed only when the Vacuum Cleaner is switched off and the motor has stopped.
Note: You can use the container with or without Plastic Bag .
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Use Plastic Bag in Material Container
Shake the filter well before emptying the container.
Fix the Plastic Bag to the steel bar.
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Plastic Bag with bar ready for container.
Fold/fix the Plastic Bag around the container.
Container with Plastic Bag ready for operation.
Detailed information about how to operate the Vacuum Cleaner is available in the Operators and maintenance manual.
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20.3. Compact Vacuum Cleaner
20.3.1. How to use
1.
Suction tube inlet
2.
Container fixture
3.
Filter unit locking mechanism
4.
Motor
5.
Filter unit
How to empty container
1.
Ensure vacuum cleaner motor is off.
2.
Remove the suction tube (1).
3.
Release the container (3).
4.
Remove the filter unit (5).
You should have a bucket nearby for the unit.
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5.
Lift and turn the container to release it from the fixture.
6.
Empty the container.
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21. Install Software
For information about software installation, see the Installation Manual for the actual machine.
Available on the Documentation DVD.
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22. Frequently Asked Questions
22.1. Machine
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My machine does not react when switching on
Please check electrical connection, do you have 230V? Is there enough compressed air, 7bar?
Check all main fuses in the MPU, see Fuse Replacement
Check all connections at the MCU behind the control panel
Check all connections at the start up button and the emergency buttons:
Safety system won’t reset
Make sure all sensors are aligned correctly, check the black dots on the side of the traverse
Are all transmitters pointing correctly to their receiver? Check if the red light is shining on the receiver. If necessary, adjust by bending the transmitter/receiver holder
During start up: X1/X2/Y servo error
This is probably caused by a defect in an amplifier board. Please contact Esko for technical support
During start up: X1/X2/Y fuse error
Check the fuse of the motor
If problem persists, it is likely to be the amplifier board malfunctioning. Please contact Esko for technical support
“Missing compressed air”
Check if you still have 7 bar at the MPU
Are the hoses not bending? Can the compressed air flow easily?
Do you hear air escaping? Check for leaks
Is the connection at the head leaking air or broken?
22.2. Tools
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After cutting, the design is dicult to remove from waste
Check tool height
After cutting, the corners are still fixed to the waste
Check tool lag
Bad quality in cutting, paper/cardboard tears
Check rotation of the tool
Offset in cut/crease lines
Check tool center offset
Offset between cut lines and crease lines
Check tool offset
Machine is milling in the carpet and table top
The milling bit is lowering inside the Chuck . Please fix the Chuck with the appropriate tool.
Milling: “Inverter not started yet”
After touching the safety unit, you need to wait for 10 seconds after resetting safety for the milling inverter to activate
If problem persists, check the connection at the tool head of the milling spindle. Is the big green cable still well connected?
Check all connections of the milling spindle: at tool head, inside cover X1 and at the inverter
Check serial connection between inverter and PC: connection OK? COM port changed lately?
If problem still persists, contact Esko
2 or 3 tools are working at the same time
Check your compressed air, make sure you have 7 bar
Check compressed air connection at the head. Is it well connected or is it leaking air?
Machine is milling in the milling underlay
Check vacuum zones. Are all necessary zones open? You can close non-covered areas to strengthen the vacuum.
Check the force of the vacuum cleaner. It happens the vacuum cleaner is heightening the milling carpets. Try to adjust the force by using the regulator on the spindle / vacuum cleaner.
22.3. iPC iPC doesn’t want to make connection with the machine
Make sure you first switch on the machine and then iPC, not the other way around
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If there was a software update recently, check if the firmware on the machine and iPC are of the same version
Check the serial connection between PC and MCU
Check the connection at the emergency button
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