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Kongsberg XP, User Manual - Product Documentation

1. The intended use is described in the How to chapter Any other use is considered non intended use Examples of non intended use e Operation by operators not meeting the requirements as described above e Unauthorized modifications bridging safety devices removing covers etc e Utilizing accessories other than those specified by Esko User Manual Kongsberg XP Non intended use may cause Health hazards and injuries Damage to the system Incorrect functionality Damage to work materials Esko is not liable for any damage resulting from such non intended use User Manual Kongsberg XP 2 9 Danger zones 2 5 1 Moving parts laser radiation and high voltage The area around the moving parts should be considered to be a danger zone 2 5 2 Noise level Hearing protection should be used by any personnel exposed to the noise from the XP table 10 User Manual Kongsberg XP 2 5 3 Ejection of parts Potential risk when running the HSMU HPMU Personnel hit by breaking milling bit or small pieces of processed material Eye protection should be used by any personnel working with HSMU HPMU on XP 2 6 Warning sign explanation Knife blades are extremely sharp Used in this documentation to indicate operations with knife blades and milling bits Potential areas with a risk of being squeezed are marked with the do not touch sign These areas are Between Y carriage and rack When the Y carriage moves
2. This material information and instructions for use contained herein are the property of Esko There are no warranties granted or extended by this document Furthermore Esko 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 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 This document supersedes all previous dated versions Correspondence regarding this publication should be forwarded to Global Support Esko Graphics Kongsberg AS Kirkegardsveien 45 N 3616 KONGSBERG User Manual Kongsberg XP Table of content t WELCOME zoinen Pee On ae is 6 1 1 POG AINA Sooo o e E A ante dle ind ec de tds ce 7 1 2 ABOUT MP GUIDE DIALOGS o a o caera loa et ras ea dra de ld o J 2 SAFETY REGULATIONS pannas ci 8 2 1 INTRODUCETTO usina ne ias o oia e a CEE Stew nT tl metre e te esc ea 8 2 2 RESPON IPILE orea ir talados 8
3. User Manual Kongsberg XP 8 14 4 Replace knife adapter To remove the knife adapter just pull it out from the holder 153 User Manual Kongsberg XP 8 15 PressCut knife tool AN Knife blades are extremely sharp 8 15 1 Description The PressCut tool is a special knife tool for vinyl cutting The cutting depth is controlled by the downward knife pressure The pressure is adjustable from the XP Guide Job setup 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 8 15 2 Replace knife blade This figure shows how the knife is fixed A special hand tool is available as an aid when inside the PressCut knife tool replacing knives Use this hand tool when removing The friction between the alignment pin A and inserting knives into the tool and the knife keeps the knife blade in place When inserting a new knife ensure the knife is correctly positioned relative to the alignment pin 154 User Manual Kongsberg XP 8 15 3 Tool pressure The PressCut tool can run with a constant tool pressure or a speed dependent tool pressure Both parameters are specified in the Job setup structure 8 15 3 1 PressCut knife down force Specify the knife pressure when running the PressCut knife tool The pressure is entered 11 as a gram value from 50 to 700 grams The knife pressure is modified if a Speed dep
4. CIO OK EG D202 Ee pozos EA FOZ04 ER AOZOS ER FOZOS Er FO205 BA Pozos BH rosin BH Fozi BA POZIZ Be Fozi4 BA FOZ15 EA D215 EE OPI POPE ER poas E F225 ae POZ27 EN Fo225 ao D220 Single Design Settings f Select the board to use and press OK I Corrugated f i RE Corrugated Inch Single design parameters ER 121258 0 1258 Kraft For setting of default parameters see rusated Metre Singe de sion parameters E 1 2008 1 200 B Kraft gt cane gate ian ServiceGuide_123Box Chapter 3 Boards M 26 1258 M 26 125 B Kran UN m 32 2008 M 32 200 B Kraft JE Mm 5s 3008 M 55 300 B Kraft hy BC 62 User Manual Kongsberg XP F0201W Inside dimensions DESIGNX1 ard Enter the dimensions to use lirside dimensions PEA a me Press Next to enter the next setup menu ETENE Note The number of menus and parameters depends upon the actual standard selected Pressing OK will bring you directly to the CAD X preview dialog This is the recommended choice if you know that the default settings are correct for the rest of the parameters Fo Peprrie id bo enezad L Accept or select your preferences in the atea Style Choice menus and press Next BA aurematica lo riai subsequent u Hae 7 Henke i es Pressing OK will bring you directly to the ire CAD X preview dialog w This is the recommended choice if you know that the default settings are correct for th
5. Ensure that the tool configuration is correct for the job and corresponds with the Job Setup information Ensure that the knife blade is sharp and proper Ensure that the Job Setup information is correct for the material If not select Job Setup file From File View select the Input File Retrieve information about required sheet size from Job View Position a sheet of material against the left ruler Retrieve information about the flute direction from the Job View window and position the material accordingly Configure vacuum zones according to the material size Switch Vacuum on Ensure that you run with a suitable Program Reference point 10 Execute the job by pressing Start 11 To repeat the job press Init and repeat this procedure from point 5 4 8 Milling Production Take care Milling bits are extremely sharp Keep away from all moving parts Ensure all other personnel stays in a safe distance from all moving parts Use hearing protectors Milling jobs should be executed in High Quality mode 75 O N O ON AWA Ensure that the tool configuration is correct for the job and corresponds with the Job Setup information Ensure that the router bit is sharp and proper for the job Ensure that the Job Setup information is correct for the material If not select Job Setup file From File View select the Input File Retrieve information about required sheet size from Job View Position a sheet of material agai
6. For this tool complete the following adjustments Tool height Measured automatically possible to add an offset value Tool Offset Adjust offset relative to laser pointer For more information about how to run the adjustment wizards see the Tool Configuration chapter 88 162 User Manual Kongsberg XP 8 19 The Ball point tool 8 19 1 Description The Ball point pen tool is available for pen drawing Tool pressure is adjustable by a knob on top of the tool 8 19 2 Tool assembly and pressure adjustment A Inner sleeve The ball point 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 8 19 3 Tool adjustment For this tool complete the following adjustments Tool height Measured automatically possible to add an offset value Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to laser pointer For more information about how to run the adjustment wizards see the Tool Configuration chapter 88 163 User Manual Kongsberg XP 8 20 Measuring foot The Measuring foot M in the illustration 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 necessar
7. User Manual Kongsberg XP 5 2 4 Camera operation Use this setting to select between a manual or automatic mode of operation 5 2 4 1 Manual detection of register marks Pointing with laser A wizard will guide you from one register mark to the next Place the laser pointer in the center of the register mark and press Start Viewing with camera This is a manual visual detection of register marks A wizard will guide you from one register mark to the next Place the camera cross in the view in the center of the register mark and press Start 5 2 4 2 Automatic detection of register marks Automatic detection The system will by means of a camera picture automatically detect the position of the register mark Circle or cross as register mark Specify if the register mark is a cross or a circle The geometry requirements are 2mm lt L lt 12 mm y limnm lt T lt 05 L A 0 08 in lt L lt 0 47 in 0 04in lt T lt 05 L 2mm lt R lt 12mm 0 08 in lt R lt 0 47 in Search If no register mark is detected inside the camera picture the system will try to search for a register mark around the expected location twice the size of the camera picture 42 User Manual Kongsberg XP 5 2 5 Workflow LDL Register on First sheet only Reading register marks will be carried out on the first sheet in a job For the subsequent sheets no register mark reading will take place The compensations calculated
8. key parameters This chapter describes the work flow from Structural design through Graphical design and print and finally to Corrugated production and how the register marks are treated in the different steps Structural design The structural design is prepared using a design software tool as ArtiosCAD The two register marks are positioned symmetric and ina known position relative to the design Rx and Ry In a company working with this system one should standardize these values and use the same offset Rx and Ry in all designs Graphical design and print The graphical design is prepared using a graphical design software tool The structural design template output from the CAD system is used to correctly position the graphics and the register marks relative to the structural design Corrugated production On the Cutting table the offset values Rx and Ry must be entered into the system When the position of the register marks is obtained offset Rx Ry is used to position the structural design relative to the register marks Rx Ry distance from Register mark to design blank 50 User Manual Kongsberg XP 5 3 8 How to make the register mark visible on the up ward side of the material e Atypical use of this alternative is when the register mark is on the down ward side of the material e Use this procedure to make the register mark visible on the up ward side of the material This is the R
9. 2 3 REQUIREMENTS TO BE MET BY OPERATORS ES 8 2 4 DEFINAN OE od dl reads S OE EE EA 8 2 5 DANGER ZONE rt ola bene badger tardado dla donas 10 2 6 WARNING SIGN EXPLANATION ct isa 11 227 ney al Sal By GIB SANA LC aS ud de Es de iE en rere tio ate o os AE e ee AET 13 2 8 PROTECTIVE EQUIPMENT conri 15 2 9 PROCEDURES IN CASE OF MALFUNCTIONS ccccccccccccsseeecccccccccseeecccccccaussecccccccuusueeeccceceuauseeeccesecauaucseececsuaacseeescess 15 3 SYSTEM DESCRIPTION ici is 16 3 1 APPLICATION PROGRAMS AVAILABLE edades 16 32 NAMING CONVENTION Sa EE a ET la ld o a ol o o de 17 3 3 OPERATING E EEMENTS prado 19 3 4 OPERATORS AN eo malta ect en aio ree o tae deciden cata saat e tias od en ado cane saa aia Oo e LEDO 20 3 5 FITCH PRESSURE AIRES STE acaba 24 A HOW TO PROCEDURES oo A la 25 4 1 loas AA IS a a AS 25 4 2 POWER ON SEQUENCE lt as ll e ge lod ad lo e o ld e ns E 25 4 3 CONTINUE AFTER SAFETY BREAK cccccccsseeeccecccccacceeeccccccccsseceeeccecccauseecececceuauseeeecescecauauceseceseceausueeescesecsuateeececeeaas 26 4 4 POWER OFF SEOUEN CE ura ada da canna ace as 26 4 5 PREPARING FOR A TOBA ed 27 4 6 OPEN AN I Tr Es a e a a a 29 4 7 CORRUGATED PRODUCIION sunt dat dt rd di dat aa 30 4 8 MIELTNG PRODUCTION unio dad dia 30 4 9 FARE BOARD PRODUCT LON EA EN E E AEE EET oia 31 4 10 CUTTING THICK MATERIALS cccccccccssseeeccccccccssceecceccccusscseeccccccuusseeececcecauseeecececeuuusceeeccecccuauseecececeuuaceeecessesuaaecee
10. 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 198 User Manual Kongsberg XP 16 3 Remove material container Note You can use the container with or without plastic bags 199 User Manual Kongsberg XP 16 4 Use plastic bag in material container Parts needed Steel ring and plastic bag Fix the plastic bag to the ring in this way BATT La yw i 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 Zefiro 75 Operators and maintenance manual 200
11. Lag 3 5 mm 0 14 inch Width 7 0 mm 0 28 inch Note After modifying these values the input file has to be re opened Lag mm Now sol 3 00 2 M dth mrn 7 00 Press Finish to save new lag settings Finish Cancel Use the lag and width parameters to achieve proper corner cutting 160 User Manual Kongsberg XP 8 17 Drill Pen tool AN Drill bits are extremely sharp 8 17 1 Tool Insert Position If included the Tool Insert Position is permanently mounted on the Z1 tool position The holder is prepared for a ball point pen or a drill tool 8 17 2 How to insert remove a drill pen tool CPA ety ES Sr rye Inserting a tool push down until the tool is inh To remove a tool press the release button locked in position 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 161 User Manual Kongsberg XP 8 18 Drill Tool 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 8 18 1 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 8 18 2 Tool adjustment
12. be zoomed View design and selected board size View design selected board size and the table size a Enters the Job Setup dialog Enter ARS registration setup dialog XP Guide is running with ARS enabled Enter ARS registration setup dialog No ARS functions are enabled Rotate direction of flute corrugated or grain folding carton Rotate direction of flute corrugated or grain folding carton CS Automatic Register System ARS 185 PrTrrrrreeeeny ra x o le te User Manual Kongsberg XP functions are disabled a Enter the Step and Repeat setup dialog Number of copies for the Step and Repeat function Enters the Matrix function Matrix function is for Folded Carton application only Button face when the Matrix function is enabled Vacuum section selection Indicates that all designs are inside the working area Indicates that one ore more designs are outside the working area 2261 1071 mm Displays the mouse pointer position relative to the selected Reference Point ooo 12 7 Preview A single click on a file in File View will display the job in the Preview window 186 User Manual Kongsberg XP 12 8 Status bar The status bar at the bottom of the GUI shows brief descriptions of various functions in the GUI The status bar can be toggled on and off from Main Menu gt View gt Status bar 12 9 Critical Warning Display When a situation that requires an a
13. button to get information about the different parameters XP Guide In XP Guide disable the Origin in lower left corner function Prepare a job setup file A reduced acceleration is recommended 30 50 It will improve the surface quality 8 11 17 Square cut out To prepare an acm file for simple cut out of a square a dedicated program is available FaceCut This program is installed together with XP Guide Procedure Generate acm file From the desktop double click the icon FaceCut The user interface appears on the screen Fill in relevant information and generate a new acm file Press the Help button to get information about the different parameters XP Guide In XP Guide disable the Origin in lower left corner function and prepare a suitable job setup file 145 User Manual Kongsberg XP 8 11 18 Miscellaneous 8 11 18 1 Warm Up To protect the spindle mandatory WarmUp is implemented If the spindle has been inactive for 8 hours or more a 3 min WarmUp is required WarmUp is started with this button File View Options Layout Help moms jejd A 2 AngleCutiO acm 28 12 06 10 59 If the spindle has been inactive for 4 weeks or more an extended sequence is required called RunIn This takes 20 minutes 8 11 18 2 Suction house Clean the suction house when necessary with acetone and a q tip A smooth surface will ease the chip removal 8 11 18 3 Vacuum clean the
14. e All test files to be used are available from the folder c xp guide iat MN e From Options gt Table options select Manual Vacuum control to ensure vacuum stays on during the complete procedure cananea E e From Main Toolbar gt Application selection select Corrugated Ka IX e From Job View Toolbar gt Select Reference point select Panel Ref point a e For this procedure use a thin sheet of carton 500 x 600 mm as test material e To continue in next chapter 55 User Manual Kongsberg XP 5 5 2 Procedure Select Options gt Registration setup gt Camera setup gt Adjust camera offset circle will be executed with your selected tool Tool for making cross P BM Knife 1 mm Jog to your wanted start position of the cross Press Start on operator panel to start execution The wizard will create a circle which will be used for offset adjustment From the drop down menu in the dialog select the tool to be used preferably a knife With a sheet of material on the table switch Vacuum on Jog to a proper position on the sheet and press Start Note In this case the position is the position of the camera The cross is made and the camera is positioned above the cross The following dialog appears 56 User Manual Kongsberg XP Pa mo ree ft By Jog and Incremental jog move the camera until the red marker is exactly in the center of the circle In the dialog press Finish In the Continue Adj
15. for the rest of the parameters 64 User Manual Kongsberg XP F0201W Glue tab dimensions DESIGNX1 ard b24f Check for correct settings and press OK falas tab dimensions E putero riai subsequent y Hae lt Previous Trini Fezinit dl 3 A Design Preview 7 3580 eset This is the CAD X preview dialog Press Job Setup if you want to verify or pa edit Tooling parameters here Could be done either here or in XP Guide later in the process When all settings are correct press Produce Box XP Guide will be displayed with the design selected and displayed in Job view If you want to look more at options available see chapter CAD X preview dialog 65 User Manual Kongsberg XP 7 System setup 7 1 Introduction This chapter will explain all functions and parameters that are important for the XP system to run properly 66 User Manual Kongsberg XP 7 2 Reference Points and Coordinate System All X and Y coordinates in the Input File uses the selected Reference Point as origin Two modes of operation are available 1 Fixed reference point Select a Reference Point from the Select Reference point drop down list e From the Select Reference point drop down list select Panel Ref K Point e Position the Laser pointer at the desired reference point e Press Init 7 2 1 The Main Reference point position Working area ll The fixed reference point number 1 is defi
16. A EEE A E EE A EE EAE A dese stave E A A 194 ET PRODUCE BO o a r a a r r 195 TS JOR ETOP e A E A A A A AA II E A 195 AO SAVE DE ION eaa oda ti ido iii AT 195 PATO OPEN DESIGN Se ie iia 195 A SSO ALE TAY ERS E EE EAE AAA AES 196 14 12 CREATE NEW BOX atra add dba 196 AS RESIZE DO ado td o e de e e UL 196 A Ea a anios 196 15 APPENDIX ROLL FEEDER cuicos ida 197 16 APPENDIX ZEFIRO 75 VACUUM CLEANER 00000 ccssssssssssssssssssccccscssssssssceccscsssssssscessccssssssesees 198 16 1 INTRODUCTION OACI C 0UN C N uo AN 198 A ETER GRAKI II II II II O eaceate eae 198 16 3 REMOVE MATERTAL CONTAINER usara lid 199 16 4 USE PLASTIC BAG IN MATERIAL CONTAINER uisii i 200 1 Welcome User Manual Kongsberg XP Welcome to a long lasting co operation with Esko The intention of this User Manual is to provide information sufficient to e Understand the main principles of the XP system e Learn how to operate the XP table in order to produce the expected result e Learn about the XP safety rules in order to operate the system in a safe way The manual is divided into the following main sections e Safety regulations e System description e How to s e Preparing for a job e Work with ARS e System setup e Tooling system e Maintenance e Appendices The main safety issues are described A short form description of the system This section is divided into two chapters e System description e Gra
17. ANTA EZ O tee er A OI TOE CY oe IO CTY 60 Va SYSTEM SETUP ai it 66 User Manual Kongsberg XP 7 1 ES A A A a Scere wend A 66 7 2 REFERENCE POINTS AND COORDINATE SYSTEM casaviidsantouwiavd aadachdevsdessdestbuaviduiass lobedsael dsdenstereuenss 67 MS PEE SE UA e DO 69 Vite FABIE SE O AA PPP aint E alta ites a Neca ities mea te iekces wegiied ities E i 71 AS SYSTEM OPTIONS cironi a E A ita de 74 AO IDISPLA COLORS esis asec essai teases ee ee ee T7 TAT A A a ata 78 TO O E A ASAA AAAA AEE AEEA 85 7 9 TOOL CONFIGURATION AND ADJUSTMENT store drid lada 88 Wee NE CORR STZ eis EEE ET 95 7 11 CHANGE FLUTE GRAIN DIRECTION ccc cccecccccccceccseeesesssssssnccccccccccccccesessssssssnsnneccccececececesessesstssssnnnececeeeeeeceeesenseeeas 95 7 12 TRANSFORMATIONS cree rss cedida london 96 ASAS SN A RET Te A A URPE EI ES SER CRETONNE RTT TERT E 98 TALA COUNTERS E TUPDALO pene ene err re ener ne rc nt TN a a 99 Tak VACUUM CONTROL E Oa ico ee e eee 100 8 TOOLING SYSTEM INTRODUCTIION cccccccccssssssssssssssssssssssssscssssscssssssccssssssssssssccesscssssssssccescsssscssesees 104 S L TOOL HANDUNGAND CARE ve E ados 104 9 2 MOOE CONFIGURATION ra aus TS a iia 105 8 3 HOW TO REPLACE A TOOL oia 107 8 4 TWO OR MORE TOOLS OF THE SAME TYPE ccccccccceeeeesesssssccccccccccccccecececeesssssssccccccccccececeececeesensssseceaenacaneceeseeees 107 8 5 MEACORINGOTAT O A O O II O O TOON RL II I IO eT EP 108 BuO ADUS MEAVY DUTA O
18. Job setup Board size gt Depth unit p Speed unit Test line 1 il UK 0 Carcel ae General information about the job setup dialog is found in the How to chapter In this chapter only the Router tool specific issues are described Specifies the router depth measured from the top of the material The depth is specified as an absolute value in mm or inch or i depending upon the Depth unit setting Not used Will display the same value as entered in the above line Specify X Y speed in or m min ips Specify X Y acceleration in Specify Z axis speed in or m min ips TTT Specify speed in RPM for Router spindle 143 User Manual Kongsberg XP 8 11 15 HSMU HPMU Table top and height adjustment 8 11 15 1 The following rules apply when adjusting HSMU HPMU T Cutting table Map table top E C Cutting underlay A Map table top function is carried out on top of the Cutting LISS T RISS underlay U Milling underlay Table top reference 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 8 11 15 2 The following rules apply when milling Mill on cutting underlay C Mill on cutting underlay Via C To avoid damage to the cutting underlay the downward movement o
19. Relative to design blank Mi e Register mark input position input e Work flow e Transformation e Registering tool e Camera operations User Manual Kongsberg XP 5 2 2 Registering tool Registration setup From the drop down menu select the tool to use for registration or No registration Laser pointer Regis Toolhead ARS camera 9 From input file Register mark positions Manual Workflow 5 2 3 Register mark input Specify how the location of the register marks is specified to the system 5 2 3 1 From input file The location of the register marks is specified in the input file provided by the CAD system 5 2 3 2 Manual The location of the register marks is entered manually 5 2 3 3 Register mark position Press the Register mark position button to enter the dialog Register mark positioning 4 Register mark positioning Measure the distance from the sheet edge to the register mark A and B The register marks is read from the acm file A X distance from sheet edge to register mark 15 mm A X distance from sheet edge to register mark 15 mm B Y distance from sheet edge to register mark 10 mm B Y distance from sheet edge to register mark 15 mm C X distance from register mark to design pa mm D Y distance from register mark to design 20 mm If your Register mark input is from input file If your Register mark input is Manual enter enter A B values A B C D values 41
20. a typical average level is 78 5 83 5 dBA and a maximum level of 98 5 dBA 2 9 Procedures in case of malfunctions Trouble shooting and repair shall only be executed by authorized personnel Contact the Esko Service Organization 15 User Manual Kongsberg XP 3 System description 3 1 Application programs available After installation of XP Guide the following application programs are available XP Guide Control program for the XP table SysLoad Program for download of updates to CU modules HWT900XP Hardware test program see separate HWT900XP User Manual FaceMill A program for face milling Prepared for HSMU HPMU 145 FaceCut A program for simple cut out of squares Prepared for knife or milling 145 16 User Manual Kongsberg XP 3 2 Naming conventions 3 2 1 Table 1 Cutting table 6 Emergency stop button 2 Traverse 7 Operator panel 3 Y carriage 8 Main power on off switch 4 Tools 9 Traverse safety stop switches 5 Main Power Unit MPU 3 2 2 Axes N 1 4 x lt Es MA TS e N H gt HE N N gt lt N paa EE a ZA 5 17 User Manual Kongsberg XP 3 2 3 The Graphical User Interface XP guide fl Edo yes Geto sat ep aii 3 The XP Graphical User Interface GUI contains these main elements 1 Main Menu 5 Preview 2 Main Toolbar 6 Job View Toolbar 3 File View Toolbar 7 Job View 4 File View 8 ARS Toolbar 9 Status Bar
21. automatic draining action of the air pressure reduction valve should be controlled Switch off the air compressor and allow the air pressure to fall 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 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 165 User Manual Kongsberg XP If the automatic draining action fails water can enter the tool holder assembly resulting in severe damage to the tool holder mechanism 9 4 Monthly Maintenance Monthly maintenance includes 9 4 1 Gears The gears in X1 X2 and Y should be re greased using the grease gun 9 4 2 Racks The racks in X1 X2 and Y should be re greased 9 4 3 Vacuum table 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 efficiency Use a steel pin 0 5 0 6 mm and with the vacuum system switched on free the vacuum holes by pushing the obstructions down into the table 166 User Manual Kongsberg XP 9 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 167 User Manual Kongsberg XP 10 Fuse replacement replacement pr
22. carried out 53 User Manual Kongsberg XP 5 4 2 Procedure Select the camera calibration wizard Option gt Registration setup Alt R gt Camera setup gt Calibrate camera Select the tool to be used when making a circle Use a knife tool Press Start to make the circle A circle will be executed with your selected tool Press Finish Press Close to continue Tool for making cross EPA Remove the material from inside the circle Jog to your wanted start position of the cross with the camera light Press Start on operator panel to start execution Click Finish when circle is done The camera dialog will be shown with the circle inside the picture If camera focus has to be adjusted do it now by turning the camera lens in or out Click the Snapshot button and the machine will move to the next point Continue to click Snapshot until all points are completed and the dialog disappears The camera is now calibrated 54 User Manual Kongsberg XP 5 5 Adjust camera offset Take care e Knife blades are extremely sharp e Keep away from all moving parts e Ensure all other personnel stays in a safe distance from all moving parts e Use ear protection Follow this procedure to calibrate the camera position relative to the other tools in the tool holder 5 5 1 General e As the camera is mounted outside the tool head cover it is important that this test is carried out with the cover mounted
23. chapter 88 150 User Manual Kongsberg XP 8 14 The Hi Force knife tool Knife blades are extremely sharp 8 14 1 Description p gt somal pa The Hi Force knife tool is a general purpose knife tool suitable for cutting a wide range of materials As the name indicates this tool is prepared for a higher tool pressure compared to the Static knife tool The tool is prepared for a wide range of knives To reduce material tear and also to keep the material down as the knife is pulled out a foot is available 8 14 2 Replace knife blade a Remove the foot by pulling the foot straight out 151 User Manual Kongsberg XP Loosen the screw A and replace the knife blade Push the knife blade against the bottom of the slit 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 8 14 3 Tool adjustment For this tool complete the following adjustments Lag setting The knife lag depends upon the blade adapter Nominal value is 0 3 mm Tool height Measured automatically possible to add an offset value Tool rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to laser pointer For more information about how to run the adjustment wizards see the Tool Configuration chapter 88 152
24. circle increases reduce the circle adjustmentvalue and rerun the test Note We recommend that the Circle lag value 2 If the radius of the circle decreases increase the circle is set to O before the first figure is executed adjustment value and rerun the test 3 Perform this test until the circle is completly circular 81 User Manual Kongsberg XP 7 7 15 Extended For each line in Job Setup an extended setup is available 3 This button face indicates that some of the extended parameters are set EO This button face indicates that none of the extended parameters are set Extended setup for line 1 2 I x Reverse score O Stop before use Stop before use d User defined text This is a user defined text Knife lift angle Lift angle Use Default Default Perf pattern A ooo 0 00 MM The extended parameters are 7 7 15 1 Reverse score Enable this check box to specify that the tool shall work on the front side of the material 7 7 15 2 Stop before use When this function is enabled the execution will stop at the beginning of this line and an operator message is displayed The text to be displayed is entered into the User defined text field Note Enable Sequencing if Stop before use is used in combination with Multi pass 33 82 User Manual Kongsberg XP IFAD Knife lift angle If the change in direction is above this value in degrees the tool is lifted If th
25. crease wheel For detailed description see separate chapters for V notch 112 HD knife tools 116 and g150 mm crease wheels 110 109 User Manual Kongsberg XP 8 7 150mm Crease Wheel 8 7 1 Description A 150mm Crease wheel mounted on an Heavy Duty Unit This crease wheel has the equivalent of 50kg 110Ib 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 A broad range of wheels with different shapes is available 8 7 2 How to mount dismount the crease wheel Insert remove the cotter pin Insert remove the latch pin 110 User Manual Kongsberg XP 8 7 3 Tool adjustment For this tool complete the following adjustments Lag setting The lag value depends upon the blade adapter Nominal value is 0 mm Tool height Measured automatically possible to add an offset value Tool rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to laser pointer For more information about how to run the adjustment wizards see the Tool Configuration chapter 88 111 User Manual Kongsberg XP 8 8 V Notch Knife tool Knife blades are extremely sharp 8 8 1 Description shee The V notch knife tool mounted on
26. for the first sheet will be used for all sheets in the job that is until a new file is opened A A Register on All sheets Reading register marks will be carried out for every sheet of material in a job 5 2 5 3 Continue with last found register mark set If for any reason reading register marks fails the job will continue using the last register mark information available 5 2 6 Transformation 5 2 6 1 Offset and rotation only The design is offset and rotated No scaling is applied To calculate rotation minimum two marks are required 5 2 6 2 Common X Y scale Uniform In addition to offset and rotation the system will calculate a scale factor Both axes are scaled with the same factor 5 2 6 3 Different X Y scale non uniform With this option offset rotation and scale is calculated allowing different scale factors for the main design axes Minimum three register marks are required 43 User Manual Kongsberg XP 5 3 Work with ARS Automatic Registration System 5 3 1 The camera window This window is available from e Registration setup gt Camera setup e It pops up each time a register mark is searched for detected Registration setup Image Camera Mise fee O Camera info 5 3 2 Camera control Three different camera control views are available from the tabs on top of window This is the default view where the camera picture is shown In the picture there is a red marker t
27. is manually adjusted Procedure using the tool height adjustment wizard Say ind don bo nenna Ihe iol owe apaa pandl buon a available from the Tool configuration dialog Gist tha Mol doin postion bir molino the lool bir dolia Uni Atocha Follow the instructions in the dialog the n tabletop base by the arrow controls beneath Current setting mm 0 41 i New setting mm z 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 For more information about how to run the adjustment wizards see the Tool Configuration chapter 88 8 16 3 How to replace the knife blade Use the spanner and the hexagonal screw driver to remove the knife blade fixing nut 158 User Manual Kongsberg XP Carefully remove the old knife blade and insert the new one Ensure the blade is properly seated Mount the nut and fix it properly Observe the alignment 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 Verify by hand that the foot movement is smooth 159 User Manual Kongsberg XP 8 16 4 Tool setup for RotaCut Lag Setting eg At left correct setting of Lag and Width values are shown
28. key 7 8 4 6 Super nudge step Defines the step the design is moved with when pressing an arrow key together with the Shift key 87 User Manual Kongsberg XP 7 9 Tool Configuration and Adjustment The Tool Configuration dialog is used for all tool settings and adjustments The dialog is available from ay e Main Toolbar gt Tool Configuration e Main menu gt Option gt Tool Configuration e Ctrl T Configuration Identified tools N Usernames NotchKnife 3 RM_Krife 1 Adjust active tool O x 7 9 1 Tool configuration and user names The tool type mounted is identified by hardware codes in each tool Current tool configuration is displayed under Identified tools When a new tool is inserted it will be identified to the system automatically Use the Usernames edit boxes beneath each drop down box to give each tool a nickname you want to associate the tool with By default the system creates a username from the tool type and its serial number F ex a knife with serial number 3020 will be named Knife 20 All tools need to be adjusted in the position they will be used 88 User Manual Kongsberg XP 7 9 2 Adjust Active Tool Select adjustment for Notchknife NotchKnife 3 Tool position 1 Select adjustment O Lag settings Rotation adjustment O Center offset adjustment O Manual adjustment of center offset and angle optional C Offset adjustment From the Adjust Acti
29. not come in contact with hard surfaces while removed from their stations either temporarily or for storage e The tools and their stations should be kept clean with a soft brush 104 8 2 Tool configuration User Manual Kongsberg XP Kongsberg XP 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 i Y sn PA ig E L Laser pointer M Measuring foot Symbols used 1 Tool alignment 2 Tool fixture 3 Tool fixture A P1 tool position see table below B camera position C drill pen ink tool holder position D P2 tool position see table below There is a space reserved for future tools in the E position Technically it is possible to put P2 tools here but none of the tools available now will work in this position 105 User Manual Kongsberg XP The following tool configuration is available Tool type Available tool inserts pa P2 HD Crease HDU Heavy Duty Unit V notch knife Yes HD knife tool Foam Cutting unit Pes HD knifetoot Pes Y HSMU High Speed milling Unit tes HPMU High Power Miling Unit Y es Y VibraCutknifetoo Fes HF VibraCut knifetool es Hi Force knifetool es RM knifetool Pes pRotaCutknifetool Pes AT O s Drill pen holder Drill tool Ball point pen Ink tool Fi
30. or High Speed mode 75 e Reduce the overall acceleration 69 e Reduce the speed and acceleration for the Job setup line 80 28 User Manual Kongsberg XP 4 5 7 Run the job Verify that the display of the job in Job View is reasonable Ensure that all settings are proper 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 4 6 Open an Input File From File View open Input Files in one of following ways ri Double click on a file Select a file and click the Open button B Click on a file hold the left mouse button down drag the file into Job View and release it When Auto Open is enabled and activated the files will be opened automatically 183 The formats available are File Oe Description extension Kongsberg acm format This is the default input format for Kongsberg XP Described acm in the Technical Reference manual for XP HPGL Described in the Technical Reference manual for XP The format is selected from the System Setup dialog 74 Standard file extensions will be automatically recognized 29 User Manual Kongsberg XP 4 7 Corrugated Production Pe W o 00 NI Take care e Knife blades are extremely sharp e Keep away from all moving parts e Ensure all other personnel stays in a safe distance from all moving parts e Use hearing protectors
31. pin When both positioning pins are in place the sheet is correctly positioned 36 4 16 2 Reference point setting User Manual Kongsberg XP Switch vacuum on IMPORTANT Remove the Positioning pins Now the machine is ready for operation When working with register bar select one of the available Reference points Option gt Table options and set a reference point in a fixed position relative to one of the Positioning pins R in the illustration This position should be used as origin during geometry design and cam file generation When preparing the job in the CAD system use the same Reference point as origin This work flow ensures exact positioning of the geometry relative to the Positioning pins 37 User Manual Kongsberg XP 4 16 3 Forced tool height measurement Follow these steps to start a tool height measuring sequence 1 Enable Incremental Jog 2 Select the Table Zero sequence 3 Press Start to execute the height measuring sequence as part of the Table zero sequence 38 User Manual Kongsberg XP 5 Work with ARS 5 1 Introduction XP offers different levels of automation for Registration mark reading Manual reading of 2 registration marks by use of laser pointer standard Manual reading of 2 registration marks by use of camera as pointing device option Automatic reading of up to 4 registration marks Linear transformation option This
32. select one tool Press the Adjust Active tool button to enter the wizard selection dialog Select Manual adjustment of center offset and angle Enter value for the Angular offset and select Activate Note that the tool will rotate as the new value is activated Press Tool override down and Jog approximate 10 cm to make a test cut Press Tool override down once more to lift the tool again UA A a Press Tool override down once more to lower the tool again 10 Note how the knife enters into the material 91 Li 12 13 14 User Manual Kongsberg XP Press Tool override down once more to lift the tool again If knife enters exact into the cut the angle is correct select Finish to exit 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 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 7 9 2 4 Center Offset adjustment AN Knife blades are extremely sharp The adjustment can be done using the adjustment wizards or by a manual adjustment procedure Wizard adjustment iP ee i N 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 Select the tool to be adjusted Press the Adjust Active tool button to e
33. sequence is pen crease v notch knife milling knife drill 4 15 3 Sequencing and knife before crease enabled Input file Execution All knife cuts are executed before crease lines The sequence is pen milling knife crease V notch knife drill 35 User Manual Kongsberg XP 4 16 Work with Register bar The Register bar is an aid when the material needs registrations that fits the requirements of a specific printing press or die cutter On XP the register bar is mounted along the X axis as illustrated at left Cutting table Register bar Register bar fixed to the table Material Material Sheet of material with pre punched holes that fit the Positioning pins on the Register bar Positioning pins Use these pins to fix the sheet of material in a correct position on the table When Register the sheet is fixed and vacuum is switched on you bar must remove the pins Cutting underlay Cutting underlay bres metas lsble for tools Area not available for tools This area is outside the working area of the machine Cutting underlay 4 16 1 Work flow Take care e Knife blades are extremely sharp e Keep away from all moving parts e Ensure all other personnel stays in a safe distance from all moving parts e Use hearing protectors pa Place the sheet of material onto the cutting table hd and align the holes in the material with the positioning pin holes sa Insert the positioning pins Positioning
34. the XP Guide CD 46 User Manual Kongsberg XP 5 3 5 Reading pre defined register marks automatically Take care e Knife blades are extremely sharp e Keep away from all moving parts e Ensure all other personnel stays in a safe distance from all moving parts e Use ear protection Select this alternative if e An ARS camera is available e Standard register marks are available on the upward face of the material on the cutting table visible to the camera e Coordinates for the registration marks are defined in the input file ArtiosCAD and Digital Flexo Suite are able to do so 5 3 5 1 Procedure e Prepare for the job as described in the User manual for XP e Select Automatic operation and options as described in chapter ARS modes of operation 40 e During execution the register marks are examined one by one and compensations are calculated before the job is completed e If for any reason the register mark is not detected the execution will stop and a picture is displayed in the GUI The following alternatives are available 1 If the register mark is visible inside the picture frame position the mouse pointer in the center of the register mark and click the mouse 2 If the register mark is not visible move the machine by manual jog until the register mark is inside the picture and press Start 3 Select Ignore this mark this register mark and press Start A7 User Manual Kongsberg XP 5 3 6 Read
35. towards traverse ends Between the table top and the moving traverse Underneath the tool head The Hearing Protection symbol indicates areas where the use of hearing protection is compulsory 11 User Manual Kongsberg XP The Eye Protection symbol indicates areas where the use of eye protection is compulsory Potential areas with a risk of being hit by moving parts are marked with the Moving Parts sign These areas are e Both traverse ends e Y carriage e Tool head s The main power unit contains main voltage and may only be opened by authorized personnel The main power unit is marked with the voltage warning sign Laser radiation The tool head is equipped with a class II laser pointer Avoid laser light into your eyes 12 User Manual Kongsberg XP 2 Safety devices 2 1 Overview The Main power switch Emergency stop Warning lamp Yellow black tape on the floor to indicate attention area Dynaguard 2 2 The Main power switch 0 The Main power switch turns power to the table on off 13 User Manual Kongsberg XP 2 3 Emergency stop button When hit the Emergency stop button switches off all power to the table 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 2 4 Yellow black tape The yello
36. workflow can be illustrated as follows XP Guide D Select and define D CAD X preview D XP Guide settings a new box select Job setup file execution This chapter will describe each step in detail When all default settings are correct the complete workflow is just a few steps illustrated as Press D Select and define Press Press Create a Box a new box Produce Box Start 60 User Manual Kongsberg XP 6 4 2 XP Guide settings For 123Box the following XP Guide settings are necessary System Di Speed setup Table 39 Display color From Option gt System setup Display units Language mm O Inch Engishus v e Enable CAD X must be enabled Input File format ACM y Enable CadX Path for jobsetup list E xp quide setup From Main menu gt File select Create a box or Open Create a box Exit 051203 backup 323a016b51d2a483420394 Program Files _rpcs RECYCLER press the Fileview toolbar gt Create a box button 13051203 backup J323a016b51d2a483420394 4Prograrn Files 61 User Manual Kongsberg XP 6 4 3 Select and define a new box Standards Catalog eq From the Create a box function the comugeted a Standards catalogue dialog is displayed CINKA Description dsc ee e Select Corrugated or Folding Carton Standards Catalog Bal From the list of standard boxes select the e EE soin PAI wanted standard template and press FOZOD Workspace
37. 1 TO DZ US Scie O ada ease eh eet a niet Coes a eect Ween ad a tas ae eee tte 172 10 6 FUSES TOOL ROTATION RECIPROCATING KNIFE ssccccccscccccececeseceesssssscccccccccccceeeccseceessssssceceesceceeeeeveeee 173 105 HPMU CHMELERRUSE ud lia li ii 174 10 8 IHPMU CHILLER HEATER FUSE cari dota da elit 175 11 APPENDICES INTRODUCTION ccoo iria 176 12 APPENDIX THE GRAPHICAL USER INTERFACE oocccccccccncnncnccnccccccccncccconononononoooononcnnocncccccoooos 177 A STE AVUATING MUN sins 43 teatsai stave uatanaete tae pauls aa haae se ns dauieonodansiteae iauis Sao hans sane E 178 User Manual Kongsberg XP 12 2 THE MAIN TOOLBAR FUNCTIONS in diia ati 180 LS a col cigs AE E EE EAA EI A E A e e LO 181 124 FILE VIEW TOOLBAR le e E ae 183 125 IO 184 12 6 JOB VIEW TOOLBAR ta a a iS E A O 185 127 PREVIEW eoe da 186 12o N 187 12 9 CRITICAL WARNING DISPLAY srt E AES 187 IA MESSAGE DISPLAY aina T oo cial 188 i i PON elo 189 12 12 ACCELERATOR KEYS uta iaa 191 13 APPENDIX INSTALL SOFTWARE counicacniniacandin caida 192 131 INSTALE XP GUIDE SYSTEM SOFTWARE cuidadoso 192 13 2 INSTALL ARS SOFTWARE esas 192 14 APPENDIX CAD X PREVIEW DIALOG eeeeessessssssooooooccsecssssssssssosooosossesesssssssssosooocossesscsssssssssssossosos 193 IA BOARDCODE roda cidcid A 193 AAA Id e er 193 A OO UNO NS al ds lo oc 194 TAA FPEUTE BUTTON A A A A EONS ECE URIS is 194 TES BCE SIDE DIA e e e e e cd pt e nea 194 o E EE A
38. 135 User Manual Kongsberg XP 8 11 10 2 If a bit is stuck If a bit is stuck in the chuck the probable cause is low air pressure To release a router bit from the chuck a pressure of approximately 7 bar is required If necessary check the table regulator setting or the pressurized air source If the bit is still stuck see the Chuck change and clean section how to unscrew the chuck 136 Chuck change and clean User Manual Kongsberg XP Clean the taper and the chuck regularly for proper operation and optimum life time of spindle and chuck 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 increases the spindle wear The IBAG chuck is lockable meaning it needs no adjustment when entering the bit Place the tool head on the table Open the chuck and remove any bit Note Never apply compressed air for cleaning Apply the 13 mm 17 mm HPMU key to hold the spindle rotor Note Do not turn the rotor when in CHUCK OPEN position This might damage the spindle 137 User Manual Kongsberg XP Enter the chuck tool with a dummy bit to the chuck Hold the rotor with the 13 17 mm key and unscrew the chuck with the chuck tool Note If y
39. 18 User Manual Kongsberg XP 3 3 Operating elements The table is equipped with the following operating elements e Main power switch e Emergency stop switch e Operators Panel 3 3 1 Main power switch On XP the Main power switch is located on the Front Panel or Revolving Work Station J Switch positions O the main power to the machine is switched OFF I the main power to the machine is switched ON 3 3 2 Emergency stop switch On XP the Emergency stop switch is located on the Front Panel or Revolving Work Station Switch positions UP the main power to the machine is switched ON DOWN the main power to the machine is switched OFF 19 User Manual Kongsberg XP 3 4 Operators panel 3 4 1 Power on e 3 4 2 Start button Ea Press this button to start operation 3 4 3 Stop button Press this button to stop operation Lit when Main power is on 20 User Manual Kongsberg XP 3 4 4 Vacuum On Off button Press this button to switch Vacuum On Off 3 4 5 Init Button Press this button to e Initialize the system i e give variables pre set values e Set Panel Reference Point If Fixed Reference Point is disabled the current position of the Laser Pointer is set as the new Reference Point 3 4 6 Table Zero Forced tool height measure Press this button then the Start button to move the tool head to Zero Reference Point which corresponds to origin in the Coo
40. 1i776 11 32 0492 13 11432 it o6s0 32 1833 3 8 jos37 118 1 611 12 o68 33 1i8o00 13 32 0582 1174 1 790 13 0 745 34 1 947 7 16 0627 13 8 1 969 14 o802 35 2005 _ 15 32 0 671 1172 2 148 15 oss9 36 2 062 1 2 o716 1578 2 326 16 o917 37_ 2 119 1732 0761 173 74 2 505 17 o974 38 2176 916 0 806 17 8 is 031 39 2233 1932 0850 2 2 862 19 ioss 40 2201 5s jogos 97 User Manual Kongsberg XP 7 13 Step and Repeat The Step and Repeat dialog is available from 00 0 e Job View tool bar button e Pop up dialog in Job view Use this function to create multiple copies of a job Step and repeat w mm Y mm T Trim distance from sheet edge G Gap distance between each item 7 13 1 Execute one at a time Execute one at a time A This function depends upon Sequencing being Number of copies 1 enabled When enabled one and one design is completed ne e If disabled all crease lines in all designs are yy oo Lipsy completed before the knife lines are carried out 7 13 2 XxY The Step and Repeat layout is available in two modes determined by the XxY check box 7 13 2 1 XxY disabled Select a suitable board size and specify the number of copies in the Number of Copies edit box The number of copies will be distributed on the specified board with Y axis priority
41. 4 User Manual Kongsberg XP The lower left corner of the job will now always be in the selected Reference Point Note i cut and ArtiosCAD users should leave this function OFF 7 5 7 Ignore Job Setup from Input file Inside an Input File it is possible to specify a Job Setup file to be used during program execution Enable this function to ignore the specified Job Setup file Note Most CAD systems do not add Job Setup file information to the Input File 7 5 8 Sequencing This function will sort the input file in order to minimize tool changes The execution order will be determined by the tool type so that pen is executed before crease which is executed before knife Some functions depend upon sequencing being active as reverse score Note i cut and ArtiosCAD users should leave this function OFF 7 5 9 Optimize tool use This function will reduce the movement with tool up to a minimum making the execution on the table as fast as possible Note i cut and ArtiosCAD users should leave this function OFF 7 5 10 Check for critical geometry Optimizes cut directions for reduced paper tear hazards Note i cut and ArtiosCAD users should leave this function OFF 7 5 11 Remove double cuts This function will remove any double cuts Used together with the layout function 7 5 12 High Quality Normal High Speed Select mode of operation 75 User Manual Kongsberg XP 7 5 13 Line to circle tolerance Specifies the ma
42. 5 X 20 mm 169 User Manual Kongsberg XP 10 3 X2 fuse Remove X2 cover Remove cover from AC amplifier unit Check fuses F2 F5 with ohm meter If blown replace with a new identical fuse Replace covers Insert main power cable into the wall socket and turn main power ON Fuse T 10A 250V 5 X 20 mm 170 User Manual Kongsberg XP 10 4 Y fuse Remove Y cover il O lt x E O uc L D gt O O v gt O E D ad N c 2 Fa WwW ro D D l E ta O E a Ln T N a E 5 8 20 oe a D Fic o O mM gt At 4 C U 2 V c lt v O e Q U L 4 Replace covers Sy a A Insert main power cable into the wall socket and turn main power ON 5 T 10A 250V 5 X 20 mm 1 Y motor with encoder 2 TCU 3 AC amplifier for Y 4 Zi motor 5 Z2 motor 171 User Manual Kongsberg XP 10 5 Z1 Z2 fuses Remove Y cover 2 On the TCU unit check i fuses Fz1 and Fz2 with ohm meter If blown replace with a new identical fuse 3 Replace covers Insert main power cable into the wall socket and turn main power ON 4 Fuse T 4A 250V 1 1 4 x 1 4 in 6 3 x 32 mm 1 Y motor with encoder 2 TCU 3 AC amplifier for Y 4 Zi motor 5 Z2 motor 172 User Manual Kongsberg XP 10 6 Fuses Tool rotation Reciprocating k
43. 7 4 3 Line Logical tools can be numbered from 1 to 99 A maximum of 30 logical tools are available Line The color defined for each logical tool is displayed in Job View as shown i The color for each logical tool number is specified in Options gt System Option e E c_M i gt 7 7 5 Tool Select the tool to be used for this line from the drop down list 7 7 6 Depth Depth can be set either in mm inch or in of material thickness Different values can be entered for With and Across the Flute With the flute Across the flute Entering a positive value specifies a depth measured from the top of the material but For knife cutting a value O specifies through cut For pen crease drill and router a value O specifies the top of the material If you specify a T value the value specifies a distance from the cutting underlay TO specifies cutting or milling through the material down to the cutting underlay A positive T value will increase the cutting creasing depth Note The T function is available only when mm inch is selected as depth unit 7 7 7 X Y speed The speed can be reduced to an absolute value or to a percentage of maximum speed haa depending upon the Speed unit setting This value affects tool down movements only 7 7 8 X Y acceleration A The acceleration can be reduced to a percentage of the maximum acceleration Y This value affects tool down movements only
44. 80 User Manual Kongsberg XP 7 7 9 Z axis Speed gt The speed can be reduced to an absolute value or to a percentage of maximum speed depending upon the Speed unit setting 7 7 10 RPM Specify RPM for the HSMU HPMU spindle 7 7 11 Laser pointer Ignore This function specifies the behavior of lines with tool type No tool Function disabled the line is executed using laser pointer verify mode Function enabled the line is ignored during program execution ignore mode 7 7 12 Knife before crease Use this function to force all knife movement to be executed before the crease movements Normally this option should be turned off It is recommended to use this option if the crease lines are done with a V Notch tool 7 7 13 Test line n Select this function to execute a test figure with the selected tool n The figure executed is a square 40 x 40 mm 1 6 x 1 6 inches Use this function as a quick way to verify correct adjustments for the different tools 7 7 14 Circle adjustment line n The Circle lag parameter determines the quality irci Circle Test of circles when cutting with knife Jog to a suitable place on the table R 15mm The value will be different for different materials Press Start to execute the test figure once CO R 40mm Complete this wizard to obtain a proper 5 adjustment of the Circle lag parameter i Select between two different circle sizes R 15 and R 40 mm 1 If the radius of the
45. Manual Kongsberg XP 8 11 8 HSMU HPMU precautions 8 11 8 1 Spindle motor power consumption supervision The router is prepared for continuous operation between O 100 Watt Too high spindle power consumption indicates critical conditions for the motor and immediate actions should be taken e Use correct and sharp milling bit e Use correct RPM for the actual bit and material e Reduce the X Y speed If the motor is running above a critical limit the execution will stop and a message is displayed 8 11 8 2 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 HSMU 60 000 HPMU 8 11 8 3 Keep distance d small d 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 lt Q Ai y 127 User Manual Kongsberg XP 8 11 8 4 Air valve operation 3 Never operate the air valve while the spindle is running This will destroy the spindle 8 11 8 5 Air pressure Never run IBAG spindle with air pressure disconnected This may destroy the spindle Keep this in mind also for test purposes 8 11 8 6 Use clean air The spindle is sensitive for the pressurized air quality Regularly check the air pressure red
46. NI omita leed lll dd rl desu lidad 109 G7 gt OLS OMM GREASE WHEEL idad oia 110 8 8 W NOTEH KNIFE TOOL in bcossdendoonsuscoerssdevosmseutbeduedendoomadatunesssduwoceabstbedveduedsamaiiatueecssdewosesbptbedvodendsamadauoncsseuboebonaudbbacens 112 8 9 POINTE TOO rra cine pan catettecu vase aa daa ind 116 SALO O o AA A A A A angie ates 118 SL MSM ARM eat cc d00e 122 98 12 THE VIBRACUT KNIFE TOOL id as 147 Solo RM KNIFE TOO RIGIDO MATERIAL rara da y EAE 150 914 THE HI FORCEKNIFE TOOL o dr llo a 151 90 15 PRESSCUT KNIFE TOOL recano a yatub odode uadeusinodubaenbumseysesearetdatendaesss 154 OSLO ROT A CONT TOOL trail toilet A 157 SLF PICO a E uaa shina tates teuee deanna deat 161 Sy IRD OO Mee ssa nd tddi 162 0 19 PHE BAG POINT TO Olarra rr ATEAREN ARAIA AES 163 0 220 MEASURING FOO Musso ada 164 OZ Ll LASER POINTER toa irasictes 164 97 IMAINTENANCE Suicaenisiasitalna iria clics 165 9 1 GENERA ica 165 9 2 DATEYMATNTENANCE 32 35 salsatardsasaietsnecasdisadhoestbadondesdoasoessnssosdisadhoestbadondesdossabessnssosdisadhoustbadoniedoasaleabnssesauiaataastacioadels 165 Oe WEEKIEY MAINTENANCE iii 165 OYE MONTE MAINTENANCE oo cdo tales ao cia een Orr ees 166 9 5 MAINTENANCE EXTERNAL EQUIPMENT ia ida 167 10 RUSE REPLACEMENT ostia ca aii 168 O MB ESE ads 168 ORD X EFUS E ea tact asain tessa na aes ala acess oa aes a sila adaiisess ah oeaadaa ass esa sdeiieestaeeuitiiseeseeaote 169 O IS O A 170 POLE a Ol al a PU Pe E nT TOO TO nv a 17
47. P Extreme care should be taken when inserting the knife foot again Keep fingers away from knife as illustrated at left 8 12 3 Tool adjustment For this tool complete the following adjustments Lag setting The knife lag depends upon the blade adapter Nominal value is 0 3 mm Tool height Measured automatically possible to add an offset value Tool rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to laser pointer For more information about how to run the adjustment wizards see the Tool Configuration chapter 88 149 User Manual Kongsberg XP 8 13 RM Knife Tool Rigid Material AN Knife blades are extremely sharp 8 13 1 Insert remove knife blade Use a 3 mm Allen key to fix loosen the knife Ensure the blade is correctly aligned blade No additional adjustments are necessary as the tool height is measured automatically 8 13 2 Tool adjustment For this tool complete the following adjustments Lag setting The knife lag depends upon the blade adapter Nominal value is 0 4 mm Tool height Measured automatically possible to add an offset value Tool rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to laser pointer For more information about how to run the adjustment wizards see the Tool Configuration
48. The minimum value should be within 0 1 8 mm 0 004 0 3 7 14 2 Counter thickness fixed value The specified value is used as the matrix thickness The fixed value should be within 0 1 8 mm 0 004 0 3 7 14 3 Counter function enabled Use this check box to enable disable the counter function The Matrix button in the File View toolbar will change face accordingly La The Counter function is available but disabled The Counter function is enabled 99 User Manual Kongsberg XP 7 15 Vacuum control Note Vacuum quick release and vacuum section selection will not work before the Vacuum push button on the Operator panel has been operated once 7 15 1 Vacuum control modes Two control modes are available selectable from the Option gt Table setup dialog e Disable I Cut controlled function to select XP vacuum control e Enable I Cut controlled function to select i cut vacuum control 7 15 2 XP vacuum on off control Vacuum control From Option gt Table dialog two modes of vacuum C l Cut controlled control is available e Manual the Manual control function is C Manual Control enabled Vacuum on off is controlled from the Vacuum push button on the Operator panel 1 Timeout after job sec e Automatic the Manual control function is disabled The function is illustrated as follows 30 min A E Job Timeout C D B Vacuum is switched on using the Vacuum on push but
49. The purpose of the program is to offer a simple work flow for preparation and production of standard corrugated and folding carton boxes The solution is based upon a CAD X implementation using ArtiosCAD functions to select a design from a library enter dimensions and generate a cut file The cut file is automatically opened in XP Guide ready to be cut on the Kongsberg cutting table for description of ArtiosCAD and CAD X see separate chapters It is a pre requisite for this function that ArtiosCAD is installed and configured for CAD X on the front end PC In Service Guide for 123Box chapter 3 and 4 you will find a description of how to install and configure the ArtiosCAD software A license key is required for ArtiosCAD to run properly 6 2 ArtiosCAD short introduction Design Manufacturing and Communication for Packaging e ArtiosCAD is the world s most popular structural design software for packaging design e With dedicated tools specifically designed for packaging professionals for structural design product development virtual prototyping and manufacturing ArtiosCAD increases productivity throughout your company e ArtiosCAD is the ideal product for all corrugated folding carton and POP display designers Artios CAD s Design Modules are the best there are today e The design and drafting tools of ArtiosCAD include functions that structural designers need to get their job done accurately and efficiently e The tool ali
50. User Manual for Kongsberg XP systems 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 A Publication of Esko Copyright 1984 2014 Esko This copyright does not indicate that this work has been published All rights strictly reserved Reproduction or issue to third parties in any form whatever is not permitted without written authority from the publisher Esko reserves the right to change specifications without notice ESKOC gt Esko Graphics Kongsberg AS www esko com Document number D3094 P O Box 1016 N 3601 Kongsberg Norway Status 131128 Tel 47 32 28 99 00 Fax 47 32 28 85 15 32 28 67 63 User Manual Kongsberg XP Change record 07 07 2010 29 09 2010 07 02 2011 25 02 2011 31 03 2011 jhbe jhbe Stop before use chapter has been modified jhbe jhbe jhbe Added chapter about Zefiro 75 vacuum cleaner for HSMU jhbe HPMU High Power Milling Unit new tool head introduced ARS chapter updated General clean up jhbe HPMU some updates 24 08 2012 Forced tool height measurement chapter added 19 10 2012 About XP Guide dialogs jhbe 3 4 13 added Manual belt clamp jhbe 7 4 3 Table top reference one issue added 22 05 2011 03 10 2011 22 10 2011 08 06 2012 23 06 2012 24 10 2012 jhbe 08 04 2013 jhbe 10 07 2013 _ jhbe 28 11 2013 jhbe A O Copyright Esko All rights reserved
51. XP 7 5 System Options The System option dialog is available from e Main Menu gt Options gt System Option e CTRL AIt O Speed setup Table System Display color Display units Language mm O Inch Enalish us Input Enable Cadx Path for jobsetup list c xp quide setup ia Origin in lower left comer Ignore job setup from input file Optimization Check for critical geometry Remove double cuts Normal v i 0 100 Line to circle tolerance mm Yacuum Router Park Position Select the System tab The following selections are available 7 5 1 Display units Select unit to be used for the GUI 7 5 2 Language Select language for the GUI 7 5 3 Input File Format Select one of the available ACM or HPGL formats in the drop down list ACM is the standard CAM format 7 5 4 Setup Enter this dialog for advanced input file format setting For ACM and HPGL use the setup dialog to specify the programming increment for the input file For DXF CF2 DDES ARD see ArtiosCAD User manual for more information 7 5 5 Enable CAD X CAD X enabled allows for the following input formats in addition to the formats mentioned above DXF CF2 DDES ARD If none of these formats are used leave the function disabled 7 5 6 Origin in lower left corner Causes the entire input file coordinates to be offset using the lower left corner of the job as reference 7
52. a Heavy Duty Unit 8 8 2 How to insert remove the V notch knife tool 1 Turn the V notch knife tool correctly to 2 Insert the first latch pin fit the alignment pin 112 User Manual Kongsberg XP 3 Insert the cotter pin 4 Insert the second latch pin and cotter pin 8 8 3 How to replace a knife blade Mee A A ld im i j pli j DY A j j This picture shows how the knife blade is 1 Loosen the two screws 2 of the knife blade aligned using two guide pins beneath the clamping blade clamping 2 Carefully remove the blade 1 3 Insert a new knife and make sure that it is aligned with the alignment pins 3 in the tool head 4 Mount the new tool Note the position of the guide pin 5 Select Option Tool Configuration CTRL T Adjust active tool Tool height calibration wizard to assure correct height of the new knife 113 User Manual Kongsberg XP 8 8 4 V notch knife modes of operation Note V notch knife adapters for different angles are available The programming and operation will be similar to the 45 degree version shown here Single Cut Set from Job setup Extended Double Cut 1 This is the default mode if neither Single Cut nor 4 Cut are enabled 4 Cut 1 Set from Job setup More V notch 1 itis a pre requisite for this function to work that the Sequencing function is enabled set from System Option dialog 74 8 8 5 About tool adjustment e Fo
53. all software 13 1 Install XP Guide system software A detailed description of the installation of XP Guide is found in the installation manual 3090_InstallationMan_xp_us available on the XP Guide CD 13 2 Install ARS software For the ARS option to work properly a Scorpion sw installation has to be completed You will find a detailed description in the service guide for XP 3115 ServiceGuide_XP_ARS pdf available on the XP Guide CD 192 User Manual Kongsberg XP 14 Appendix CAD X preview dialog Design Preview 7 35en Size 1836 5 x BO 5 Crete 4 new Box Resize Box DESIGNS ARD A This dialog is used when importing DXF CFF2 or DDES files and when opening ArtiosCAD designs ARD The dialog shows the design as read by CAD X At the lower left there is a field showing operator messages 14 1 Board code Board code Display the selected board code Board code is a code used in the M SBS 250 actual factory to identify the boards available 14 2 Size Size 1836 5 x 602 25 Display the size of the design X x Y in selected units mm or inch 193 User Manual Kongsberg XP 14 3 Zoom functions a Zoom rectangle Push the button Use the mouse to select the preview area you want to see in the window al Zoom out Push the button to expand the view Scale to fit Preview is scaled to fit the window 14 4 Flute button Display the flute or grain direction Direction may be altered by push
54. amera until the centre cross is exactly on top of the register mark Press Start to continue execution e After the last register mark is found the compensation parameters are calculated and the job is completed 48 User Manual Kongsberg XP 5 3 6 2 Procedure using laser pointer Prepare for the job as described in the User manual for XP After Start the execution will stop for each register mark By manual jog move the laser pointer into the center of the register mark Press Start to move to the next register mark and repeat the procedure After the last register mark is found the compensation parameters are calculated and the job is completed 5 3 7 Reading manually defined register marks Take care e Knife blades are extremely sharp e Keep away from all moving parts e Ensure all other personnel stays in a safe distance from all moving parts e Use ear protection Select this alternative if No pre defined register marks are available in the input file 520 61 Procedure Specify Manual Register mark input and other Registration setup parameters as described in chapter ARS modes of operation 41 Enter the X Y distance from the register mark to design blank see 41 Depending upon the selected mode of operation follow one of the procedures for reading pre defined register marks as found in chapter Work with ARS 44 49 User Manual Kongsberg XP 5 3 7 2 Manually defined register marks
55. ashing 25 User Manual Kongsberg XP 4 2 6 Table zero sequence Press Start pushbutton to complete the table zero sequence The machine will move to current selected reference point The table is now ready for operation 4 3 Continue after safety break If the Safety system is activated all movements on the table are stopped and the Warning lamp on top of the Y carriage 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 Stop pushbutton 4 4 Power Off sequence When power off follow this sequence 4 4 1 1 Servo power off Press the Servo on pushbutton to switch servo power off 4 4 1 2 Table Power Switch Table power off using the Main Power switch 4 4 1 3 Front End PC To switch off the PC use the Operating system shutdown procedure 26 User Manual Kongsberg XP 4 5 Preparing for a job 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 operation make sure that e the table is free from obstructions e no personnel come close to the table Use this chapter as a check list when changing from one job to another 4 5 1 Job Setup oo l E Job Setup is a table that links MC_FATI 260071500 ju gt fi E Logical tool numbers P numbers STi in the Input Fil
56. ber tip tool 106 User Manual Kongsberg XP 8 3 How to replace a tool E When mounting a tool head onto the Z1 or Z2 tool positions ensure that the alignment pins and the electrical connector on the tool head fits those on the bracket y y N Use an Allen key 6 mm to fix the tool head Ensure both screws are properly fixed 8 4 Two or more tools of the same type Each tool is identified to the system by 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 Inside each tool there is a Tool Board By means of dip switches you can specify 4 unique tool numbers as illustrated at left The different tool numbers are defined as follows Tool board switch setting Tool 1 1 amp 2 off Tool 2 1 on 8 2 off Tool 3 1 off amp 2 on Tool 4 1 amp 2 on p ln toot ip 2 12 107 User Manual Kongsberg XP Note Depending upon the tool type 2 or 4 individual tools can be specified 8 5 Measuring station XP is equipped with a Measuring station The Measuring station eliminates the manual adjustment of tool height The Measuring station covers the following functions e Calibrat
57. chapter will cover all ARS related issues The camera solution used in ARS is based upon a Scorpion software package Thus it is a pre requisite that Scorpion is properly installed and configured together with XP Guide in order to make ARS work Note The Job layout function is not available when running ARS 39 User Manual Kongsberg XP 5 2 ARS modes of operation 5 2 1 Introduction All settings described in this chapter are available from the Registration setup dialog available from NN XP Guide gt Option gt Registration setup Job view toolbar gt Enter ARS registration setup dialog The button change face depending upon if ARS is running or not XP Guide is running with ARS enabled Job view toolbar gt Enter ARS registration setup dialog No ARS functions are enabled _ Registration setup Registering tool Transformation No registration Register mark input Different X Y scale Camera operation Register mark Register mark Workflow Transformation Registering Camera Execution input position input tool operations From input Relative to sheet edge Laser pointer Manually by wizard file Ball sheets Offset and rotation Manual Point by laser Common X Y scale View by camera Camera E m utomatic Automatic Camera detection Different X Y scale The mode of operation is specified by 3 4 parameters as illustrated above First sheet only Relative to sheet edge Manual
58. ction from the operator occurs in the system the following message box will be displayed Critical warning x Critical warning 4002 Cannot Open TVRECT ACK Additional information may be achieved in the Message Display 187 User Manual Kongsberg XP 12 10 Message Display I e The Message Display is available from the Main Toolbar button MM Message display Info XP Guide 3007 Jun 9 2008 09 22 18 Info Started Wednesday June 11 008 09 08 Info MCU 4 3007 Date 2008 06 09 Time 1 44 Info SEU Y 3007 Date 2008 06 09 Time 8 14 Info TCU Y 3007 Date 2008 06 09 Time 8 15 Info TableT ype RP ae Info gt Info Tool 1 calibrated to 1921 Info 4 Popup on warnings Show All v Always on top Log messages The Message display offers additional information when troubleshooting the system Normally you will get all the necessary information from the pop up Critical Warning Display For additional information please examine the Message Display Pop up on warnings Check this box if you want warnings to be automatically displayed Always on top Check this box if you want the Message display to stay on top Log messages The system is prepared for output of additional system information useful for service and troubleshooting For normal operation disable this function to reduce the amount of messages Show The type of information displayed in the Message display can be configur
59. d for adding or L Set reference points Table setup Set ruler position Table top reference Map table top surface changing the table reference points Procedure Press the Set Reference Points button to set up any fixed reference points Follow the instructions given by the wizard and define the number of fixed references you want As many as 10 points can be defined Click the OK button Register table size Adjust x1 to X2 angle 7 4 1 1 i cut Main reference Calibrate foot on the measuring station Press this button to establish the correct Main reference Adjust measuring station position j f point for i cut operations Vacuum control C l Cut controlled 2 vacuum pumps Use pump 1 Use pump 2 7 4 2 Set Ruler Position If your table is equipped with rulers please follow the procedure below If not enable the Do not use rulers 0 Timeout after job sec checkbox in the Set Ruler Position dialog Conveyer For the table to operate properly an exact registration of C Split sheet feed the ruler positions is necessary This is a one time job but it can be necessary to repeat the procedure if Sheet feed correction 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 Procedure Press the Set Ruler Position button Follow the instruction given by the wizard and define the left ruler posit
60. e is no cut before Cancel Help 7 7 16 3 Reciprocating knife with motor off Enable the function Run reciprocating knife lines with reciprocation off to run the Reciprocating knife with motor switched off 83 User Manual Kongsberg XP 7 7 16 4 Disable material thickness measurement When this function is enabled no material thickness measurement is carried out The following rules apply e In Job setup the T function must be used for depth settings e In Job setup the Depths unit must be set to mm inches Percent not allowed e During tool up movements the knife is lifted to its top position Note This function is for knife tools only 7 7 16 5 Extra lift of tool Add extra lift height to tools when moved in up position Useful for warped boards or uneven Surfaces 84 User Manual Kongsberg XP 7 8 Job Layout XP Guide can operate in either Single Design Layout mode or Multi Design Layout mode 7 8 1 Single Design Layout ee Press the Single Design Button to select Single Design layout mode ons Layout Help When a design is opened in this mode it is always located relative the selected reference point Only one design can fh be placed on the table It can be further manipulated with I A fh Rotation Scaling or with Step and repeat 7 8 2 Multi Design Layout ons Layout Help Ij j je Press the Multi Design Button to select Multi Design layout mode When a design is opened fro
61. e knife tool has a lag the knife lift angle is 14 degrees 7 7 15 4 Perf pattern YA Specify a perforating pattern in the two edit boxes The first specifies a tool up length and the second a tool down length 7 7 16 More xj The following functions are available through the More button M Knife overcut Enable knife overcut 7 7 16 1 OverCut Check this box to enable or disable the Knife Over cut function Applies to knife SS ES tools only 008 ies Poo i Specify the size of the over cut at start and end of consecutive cut lines When the direction change between two Are to lines consecutive lines is bigger than 13 5 A AS degrees an over cut corner action is Seonccccvsconsescenvocesonocevecsccoveccarscqosecqneccocosocoseces performed 2 7 7 16 2 Arc to Line Arc to Line will apply to knife tools only Radius less than 0 00 mm The radius is the maximum radius where the Arc to Line function will be executed Reciprocating knives In order to make a more correct cut this function will minimize angular and sideways forces onto the cutting knife Run reciprocating knife lines with reciprocation off Material measurement This is achieved by splitting circles into Disable material thickness measurement straight line segments and turn the cut direction for each segment Thus the Extra lift of tool knife is lowered into the material where 0 00 TN ther
62. e layer contains all dimensions and so on layers Use this option to verify your settings 14 12 Create a new box Create a new Box Start from the beginning select and specify a new box 14 13 Resize Box Resize Box Enter dialog for modification of box parameters 14 14 Exit Close this dialog 196 User Manual Kongsberg XP 15 Appendix 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 197 User Manual Kongsberg XP 16 Appendix Zefiro 75 vacuum cleaner 16 1 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 HSMU HPMU motor damage 16 2 Filter shaking EA i Filter shaking is important in order to maintain a good vacuum cleaner performance
63. e rest of the parameters Parel sequence E aT LeeL E TALA E ELA WELL ET C LALA gt GT F0201W Detail style choices DESIGNXA ard Check for correct settings and press Next Slat styles tetai ste cheeses tt tti LF AREY SLPS i ma mS LS i LA pi i Pressing OK will bring you directly to the Berke Major Hap skit CAD X preview dialog qua ed br Squared Comte This is the recommended choice if you na know that the default settings are correct l 0 Bounded sjtaper for the rest of the parameters Minor fep slot Sa vutaper squared O Squared tapar FM haunded F Rounded mitaper Aura ed Rownded wtaper 63 F0201W Minor panel slot DESIGNX1 ard B2 F0201W Flap sizes DESIGNX1 ard User Manual Kongsberg XP Check for correct settings and press Next Pressing OK will bring you directly to the CAD X preview dialog This is the recommended choice if you know that the default settings are correct for the rest of the parameters Check for correct settings and press Next Pressing OK will bring you directly to the CAD X preview dialog This is the recommended choice if you know that the default settings are correct for the rest of the parameters Check for correct settings and press Next Pressing OK will bring you directly to the CAD X preview dialog This is the recommended choice if you know that the default settings are correct
64. e to physical tools on fathdcrease the machine and describes their fatvnotch behavior 78 The Job Setup information is stored as a file on the front end PC Select Job Setup file from the Job Setup drop down list A H 1 Position the material for the job on the oo table MC_FAT1 26001500 E 500 lu y i rn pe from the Board Size 10001 000 Note Board size information is used for Ne 26007500 MA 600 590 calculating Step Repeat If Step amp None Repeat is not used this setup is optional 27 User Manual Kongsberg XP 4 5 3 Open an input file From File View open files in one of following ways Double click on a file e Select a file and click the Open button Click on a file hold the left mouse button down drag the file into Job View and release it When Auto Open is enabled and activated the files will be opened automatically Use the Toggle Flute Direction button to set correct direction for the actual job 4 5 5 Vacuum Section Setup From the Vacuum Section setup dialog configure a suitable vacuum area for the job 4 5 6 Select proper speed The machine speed during execution will have important impact on the final result For some combinations of tools and materials you can run with full speed for other combinations the speed and or the acceleration has to be reduced For this purpose the following alternatives are available e Select between High Quality Normal
65. ed as follows Open the Job Setup file for editing Identify line for reverse score or add a line for this function Open the More dialog for this line enable Reverse score When executing the job with this Job Setup selected the Reverse score function will be carried out for the specified logical tool s 5 Follow the instructions displayed when executing the job eh The picture shows a Job Setup with reverse creasing using logical tool no 1 x Job setup cnet Job setup Board size Current job setup Depth unit Speed unit job 01 v Open y CAS Line 4 Tool fat gt z E P o E 4 Ho crease 20 m 60 60 100 100 O a 2 MN amp Ho cease 20 a 60 60 100 100 i 2 MN 1 be vic 1 100 100 E 00 100 5 E x LaserPointer v 100 100 Laser pointer Ignore he setup for line 1 Knife before crease Reverse score 7 Stop before use Stop before use User defined text 4 14 Work with different reference point settings To define or modify reference point settings go to the Set Reference point wizard 72 Reference points are selected from the Job View Toolbar 185 34 User Manual Kongsberg XP 4 15 Work with Sequencing and Optimization 4 15 1 Sequencing disabled Input file Execution gt The input file is executed as is 4 15 2 Sequencing enabled Input file Execution All crease lines are executed before knife cuts The
66. ed to 1 Critical messages only 2 Critical and important messages 3 All messages 188 User Manual Kongsberg XP 12 11 Position Display The Position Display is available from e Main Menu gt View gt Position display e Ctrl D Use the set of radio buttons to select one of the available displays 12 11 1 Program reference x Prog rel X 0 00 mm Table ref C Hrandz N 0 00 di C OE POS C DEPOSZHR Cancel Help Displays table coordinates relative to program reference point 12 11 2 Table reference xi C Prog ref X 0 00 E ye Table ref C Hrandz Y 0 00 vs C OE POS C DEPOS ZHR Cancel Help Displays table coordinates relative to table reference point 189 User Manual Kongsberg XP 12 11 3 Tool Rotation and Z axes Position display Display Z and Tool Rotation positions e Z shows actual distance from Z axis zero position e Tool Rotation shows actual angle from Tool Rotation zero e Material thickness shows measured thickness of material on the table O 12 11 4 Encoder count X and Y a Position display Shows encoder input as read for X1 X2 and Y encoders 12 11 5 Encoder count Z and Tool Rotation Position display Shows encoder input as read for Z and Tool rotation encoders 190 User Manual Kongsberg XP 12 12 Accelerator Keys wy O rmen IN Ca IE NN 191 User Manual Kongsberg XP 13 Appendix Inst
67. egister mark which in this case will be on the down ward side of the sheet when cutting and creasing is carried out Place the sheet on a soft surface and use an awl to make a hole through the material Keep the awl vertical as you apply pressure 51 User Manual Kongsberg XP On the rear side use the awl to round the hole Now you have transferred the Register mark to the opposite side of the sheet Repeat the procedure for the second Register mark 52 User Manual Kongsberg XP 5 4 Camera calibration Take care e Knife blades are extremely sharp e Keep away from all moving parts e Ensure all other personnel stays in a safe distance from all moving parts e Use ear protection 5 4 1 Introduction To achieve maximum accuracy when using ARS the camera should be calibrated relative to the laser pointer Camera calibration is a three step process Knife tool used 1 The knife tool to be used for camera for calibration calibration is calibrated relative to the laser 6 lt eS Camera to pointer a be calibrated 2 The camera is calibrated relative to the knife Pi tool 3 The camera position relative to the laser y pointer is calculated based upon the previous Laser pointer two calibrations Knife tool calibration is not included in this procedure it is available in the Tool section It is important that the knife tool calibration procedure is completed before this procedure is
68. elected reference point position in current laser pointer position Park position a E at end of job The park position is in the lower right corner of the rectangle enclosing the job Set park position in current position Press this button to established a park a 7 6 Display colors The Display colors dialog is available from e Main Menu gt Options gt System Option e CTRL AIt O Select the Display Color tab This dialog defines what colors to be used for each line in Job Setup when a job is displayed in Job View Colors are changed by clicking on any of the combo boxes and selecting the wanted color Additional lines can be added at the bottom of the list 27 User Manual Kongsberg XP 7 7 Job Setup 7 7 1 Introduction Job Setup is a table that links Logical tool numbers P numbers in the Input File to tools on the machine and describes their behavior The Job Setup information is stored as a file on the front end PC Notes e All Job Setup files must have extension mat e All Job Setup files have the identifier FMT 2000 as the first line in the Job Setup file Typically the Job Setup is different for the different materials used Therefore it is recommended to have one Job Setup file for each material type used 7 7 2 Select Job Setup files Selection of Job Setup files is available from e Select a Job Setup file from the drop down list in Job View p tata 4 e Invoke the Job Setup dial
69. endent pressure is specified see below The tool pressure specified in the Job setup structure is automatically adjusted During the tool down movement the PressCut tool moves down until the material surface is detected and the proper knife pressure is achieved The tool pressure will vary depending upon the material For a typical vinyl cutting job a recommended start parameter is Pressure 65 70 gram and Speed dependent pressure 50 Note For the PressCut knife tool to work properly a sharp knife is very critical Pay special attention to the tip of the knife as it is easy to break 8 15 3 2 Speed dependent knife down force oF The Speed dependent pressure function adds pressure to the PressCut knife tool len depending upon the speed of the machine The function can be illustrated as follows Speed 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 pressure level is as specified by the PressCut knife down force parameter see previous chapter Pressure Distance Curve B illustrates the knife pressure when the Speed dependent pressure is set to 100 When running at full speed the pressure is the double of the PressCut knife down force 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 highe
70. ere Gg OR eter Re ee VS ee er EO Sensor failure cable defective connection failure sensor defective Water level of water flow too low HI Temperature of cooling medium too high O tite eae ae es Smeg AAA Le eee ne Temperature of cooling medium too low 125 User Manual Kongsberg XP 8 11 7 HSMU HPMU safety issues 8 11 7 1 Suction house Always when executing a job let the suction house float on top of the material In addition to chip removal the house reduces the risk of being hit by small work pieces or by a breaking router bit 8 11 7 2 Eye protection Use eye protection when working with HSMU HPMU 8 11 7 3 Hearing protectors The noise generated by HSMU HPMU highly depends upon the material processed and running parameters Use hearing protectors when necessary 8 11 7 4 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 8 11 7 5 Router bits Router bits are very sharp handle with care Never touch a rotating bit Ensure the warning lamp is dark and also observe that the bit is not rotating before approaching the bit Always insert a dummy bit before dismounting a tool head from the machine 8 11 7 6 High temperatures Be aware that the HSMU may become hot during operation 8 11 7 7 Clean surface Keep the table and material surface clean free from obstacles 126 User
71. es the Measuring foot e 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 e During the first Table zero sequence after power on e After any tool change and the tool is not calibrated e After the safety system has been broken for 30 sec or more e After the servo system has been off for 30 sec or more It is possible to start a tool measuring sequence manually see Forced tool height measure 38 8 5 1 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 hole through the material Additional depth is entered in two ways 1 The general depth of a tool is entered in the Tool height wizard available from the Tool Configuration menu 88 2 The depth for a certain material or job is entered in the Job setup dialog 78 108 User Manual Kongsberg XP 8 6 HDU Heavy Duty Unit A Knife blades are extremely sharp 8 6 1 Description ALA HDU with V notch HDU with 9150 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 4150 mm
72. ess 32 4 11 MAKE A PEN PLOT uu cccccccccccsseseccccccccccsceccceccccssccsecceccccuausseeecccccuuusceeeccecccuussseecececcuausceeeccescuaausceecececsuaasesecececsuaaceseess 32 4 12 SET THE TABLE UP FOR MULTI PASS CREASING OR MILLING cccccccccccsseeeeccccccccsceecccecceuseceeececececaacesccessauaseeeecess 33 4 13 JOBS INCLUDING REVERSE SCORE cccccscsssccscccccccccsscceccccccccescesecccccsccssececceccsuaessesececcsuaasseecececcuacesceeesecccuaceseeeess 34 4 14 WORK WITH DIFFERENT REFERENCE POINT SETTINGS cccssseeccccccccsccceecccccccssceecccecceuauceecececsuauceeeceeseuaaaceeecess 34 4 15 WORK WITH SEQUENCING AND OPTIMIZATION cccccsseseceeeeceecceececeececsecececeeceeeeeeeseseceeeeeseeeecesesecceseceeeeeeeeeeceeees 35 AO NVORK WITH REGISTER BAR e eee 36 5 WORK WITHUARS oo ds 39 5l TNR DUCT TON a dae do Dels di sae 39 5 2 ARS MODES OF OPERATION o a e e ol e Buses 40 5 3 WORK WITH ARS AUTOMATIC REGISTRATION SYSTEM c ccccccccccsssssccesssecessssecesssssccessssscesssseceeessseeesssseeessesees 44 5 4 CAMERA CALIBRATION vasallo dolo abia 53 SS AADJUSTCAMERNNO PRESEN a ol a col Eo de o e E el e e e a 55 5 6 VERIFY CORRECT OFFSET ADJUSTMENT ccccccccccccseeecccccccccssceeecccccccusseeccccccccuaceecececceuuaseecececeuuauceccesececuuaaseseess 58 Gs WORK WITH 223 BOM AA Ai 59 6 1 INTRODUCTION rat nd lane sados 59 6 2 ARTIOSCAD SHORT INTRODUCTION sra 59 Bis CAD SHORT INTRODUCTION a la 60 6 4 WORK
73. ete or add to the tool list The tool list contains tools that you can select for the tool positions 93 User Manual Kongsberg XP 7 9 3 1 Ignore the automatic tool identification The Ignore the automatic tool identification may be used when the automatic tool detection fails and manually tool selection is necessary Tick the box to avoid changing the tool setup when zero point sequence is running or tool identification button is selected 7 9 3 2 Delete tools The selection Delete tools may be selected when a tool is no longer in use For example when the tool is returned to factory or is malfunctioning The button Delete the tool remove the tool selected in the Tool dropdown list from the tool list 7 9 3 3 Add tools The selection Add tools may be selected to add new tools or tools that fail to be automatically detected The button Add the tool attaches the tool selected in the Tool dropdown list to the tool list 94 User Manual Kongsberg XP 7 10 Board size The list of available board sizes is maintained from the Board size dialogue available from e Main Menu gt Options gt Board Size setup 4 e The Job View toolbar button select the Board Size tag e Pop up dialog in Job View e Ctrl J Job setup Job setup Board size Avallable board sizes Unit mm To edit already defined boards edit the values directly in the table To add new boards go to the last line in the table and add the new material t
74. f the drill bit is stopped 2 mm 0 08 inch above ASOC SS 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 Milling underlay on top of cutting underlay To be able to mill through the material the thickness of the Y M u C milling underlay must be gt 2 mm 0 08 inch p A VA If the thickness of the milling underlay U is lt 5mm 0 2 KK KK KO inches the tool height will follow the mapped table top Stiff underlay on top of A stiff milling underlay S on top of the cutting cutting underlay underlay M Y P C 2 a Y If the thickness of the milling underlay S is gt 5 mm 0 2 inch the underlay is supposed to be more or less stiff SoS SONNE SONS ONE One typical milling underlay material is MDF face milled on top In this case when the underlay is supposed to be stiff the measured table top reference value is used for height control 144 User Manual Kongsberg XP 8 11 16 Face milling For face milling an acm file prepared for the actual material is required A program dedicated for this purpose is installed together with XP Guide Procedure Generate acm file From the desktop double click the icon FaceMill The FaceMill user interface appears on the screen Fill in relevant information and generate a new acm file Press the Help
75. find more information about this issue in the Technical Manual for XP i ink te thls decane 179 User Manual Kongsberg XP 12 2 The Main Toolbar functions The left part of the Main Toolbar contains the following general functions Corrugated Y I PS gt PIA 2 HL g Selects application from the drop down list View the Message Display 188 Enter Tool Configuration 88 Set Single Design operation 85 Set Multi Design operation 85 Work with 123Box 59 Start HSMU HPMU spindle warm up HSMU HPMU only Start vacuum cleaner HSMU HPMU only Enter the Help system The right part contains the following functions Shows measured thickness of material on the table Rewinds current job T Estimated total job time R Estimated remaining job time 180 User Manual Kongsberg XP 12 2 1 Main Toolbar configuration From View gt Toolbars you can configure the Main toolbar to show left right none of the Main toolbar 12 3 File View y if a Eo v sl a ale CAvp quideslAT File Material Sizet ty Due Flute EF ACADTEST ACM Axis xp24 acm i EP Axis_xp44 acm EP Axis_xp46 acm Y Czerol acm a Czeroz acm 7 Czergo3 acm A total of 5 columns can be displayed in the File View The file name is always displayed in column 1 The other 4 columns can be customized in the Customize File View dialog The files in the Fi
76. from Option gt System setup 3 4 11 Tool Down Press this Tool Down button to manually operate the machine with a tool in the down position Cancel by pressing Tool Down a second time 3 4 12 Vacuum release mode For details about this function see separate chapter Vacuum control 100 22 User Manual Kongsberg XP 3 4 13 Manual belt clamp In order to manually drag material onto the cutting table using the conveyor belt the Manual Belt clamp function is available The Manual Belt Clamp function is enabled after the Vacuum release button has been kept down for more than 2 secs Y The Manual Belt Clamp function is active as long as the Vacuum release button is kept down TT As long as the Manual Belt Clamp function is active the following actions are carried out e The belt clamps are activated e The feeder paws are activated e The operator panel jog buttons are available for manual movement of the traverse conveyor belt All other possible actions on the machine are inhibited e Acceleration is reduced during belt movement 23 User Manual Kongsberg XP 3 5 High pressure air system 3 5 1 General The High Pressure Air System supplies the valves and tooling with compressed air _ Pressure Regulator Valve To Tool Holder T Pressure Gauge Compressor A Water Trap For details regarding air supply requirements see Site Preparation manual 3 5 2 Air regu
77. gnment and snapping features provide graphical feedback helping both experienced and new users immediately become more productive e Complete 3D integration allows for quick prototyping of designs and presentations eliminating communication errors and reducing design review cycles e ArtiosCAD s layout and tooling design features can be used to create plate layouts and die tooling optimized for the production equipment that will be used in manufacturing e The integrated database and reporting features enhance communication within your company as well as with external suppliers ArtiosCAD s Adobe Illustrator plug ins truly creates the first round trip workflow for structural and graphic designers Key benefits e Superior drafting tools increase packaging designer productivity e Smart Standards save time and reduce errors e 3D modeling and design provide fast prototyping and presentations e Powerful and efficient layout and tooling design reduce production costs e Relational database offers flexible library searches and reports 59 User Manual Kongsberg XP 6 3 CAD X short introduction e CAD X is a software module that makes it possible for other programs to use functions from within ArtiosCAD e The CAD X software is installed as part of XP Guide e Itis a pre requisite for CAD X to run properly that ArtiosCAD is installed on the PC before installing XP Guide 6 4 Work with 123Box 6 4 1 Introduction The 123Box
78. ing direction The milling direction is important in order to obtain a good result Correct directions especially in foam materials are illustrated in the figure at left The blue part is our product where we want the edges to be smooth and nice Note Altering the milling direction is to be carried out in the CAD program 8 11 9 7 PressCut knife tool in combination with HSMU 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 133 User Manual Kongsberg XP 8 11 10 HSMU HPMU bits and bit change 8 11 10 1 How to insert replace a router bit Ensure the spindle is not running lamp is dark Mind the sharp bit and move the suction house up Lock the house in its up position Observe that the bit is not rotating Use a cloth to hold the bit Move the lever down to open the chuck Put the bit in a proper storage container Insert a new bit Close the chuck 134 User Manual Kongsberg XP Only the round part of the shaft should be inside the chuck See the HSMU HPMU bit length and position chapter for more information Release the lock to allow the suction house moving down to its down position Regularly perform a chuck holder and chuck cleaning following the dedicated procedure Note Never apply compressed air for cleaning
79. ing pre defined register marks manually Take care e Knife blades are extremely sharp e Keep away from all moving parts e Ensure all other personnel stays in a safe distance from all moving parts e Use ear protection Select this alternative if e Register marks are available but the marks can not be recognized by the camera due to Shape or lack of contrast e Automatic register mark detection is not available e Coordinates for the registration marks are defined in the input file ArtiosCAD and Digital Flexo Suite are able to do so 5 3 6 1 Procedure using camera e Prepare for the job as described in the User manual for XP e After Start the execution will stop for each register mark and the camera picture is displayed in the GUI Two alternatives are available 1 Use the register mark by mouse click By manual jog move the camera to a position where the register mark is inside the picture Inthe picture move the cursor over the center of the register mark and press the left mouse button If the mouse click was inside the green circle the machine will move to the next register mark and the procedure is repeated If the mouse click was outside the green circle the machine will move until the click position is close to the center of the green circle Now move the cursor over the center of the register mark and press the left mouse button once more 2 Use the register mark by jog By manual jog move the c
80. ing the button i Flute Grain is along X Flute Grain is along Y 14 5 Design side display Show which side of a design that is displayed foe 14 6 Unit display Show the units used for the preview display mm 194 User Manual Kongsberg XP 14 7 Produce box Produce Bos Save As Press the Produce Box button to create the cutting file and transfer it to XP Guide Before the CAD X preview dialog is closed you are asked to save current design Save in 5 Designs D ex Edy PHDESIGNX1 ARD My Recent Documents E Desktop My Documents 59 My Computer File name DESIGNX2 4RD y My Network Save as type aces 14 8 Job setup Job Setup The recommended directory for design storage IS C esko artios designs Give the design a name and press Save After this XP Guide is displayed with the selected design displayed in Job view ready to be cut Job setup is opened for editing For more information about Job setup see XP Guide Online Help 14 9 Save design Save current design ard The recommended directory for design storage is C esko artios designs 14 10 Open design Open another design ard Same as double clicking an ard file in XP Guide File View 195 User Manual Kongsberg XP 14 11 Show all layers Show all Show all layers in a design Inside ArtiosCAD a design is separated into layers One layer contains the geometry on
81. ion 2 Ensure that the Ball point pen is proper for the job 3 Ensure that the Job Setup information is correct for the material If not select Job Setup file From File View select the Input File Retrieve information about required sheet size from Job View Position a sheet of material against the left ruler Ss 32 User Manual Kongsberg XP 7 Configure vacuum zones according to the material size 8 Switch Vacuum on 9 Ensure that you run with a suitable Program Reference point 10 Execute the job by pressing Start 11 To repeat the job press Init and repeat this procedure from point 6 4 12 Set the table up for multi pass creasing or milling Take care e Knife blades are extremely sharp e Keep away from all moving parts e Ensure all other personnel stays in a safe distance from all moving parts e Use hearing protectors Multi pass creasing is beneficial if you want a deeper crease pattern This is achieved by running one pass with for example 50 depth and a second pass with 70 dept Multi pass milling is beneficial if you want to mill through a material where the thickness is bigger than the router bit diameter Multi pass creasing or milling is available by modifications in the Job Setup file Proceed as follows 1 Open the Job Setup file for editing 2 Identify the crease or milling line where multi pass is wanted 3 Add one or more new lines with the same logical tool number and specify the sa
82. ion Repeat the procedure for the right ruler Note When the right ruler is registered use a position 100 mm out from the corner marked on the ruler 71 User Manual Kongsberg XP 7 4 3 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 The Table top reference function should be carried out e After mechanical adjustments of traverse or tool head e When cutting through material is not working properly e After any change of cutting milling underlay for instance after adding or removing the milling underlay Procedure Remove all materials from the table surface The cutting underlay remains in place If the table is equipped with a conveyor belt avoid measuring directly on the belt junction Press the Table top reference button In the wizard press OK to start measurement 7 4 4 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 If the table is equipped with a conveyor belt move the belt junction away from the table surface Press the Map Table Top Surface button Follow the instructions given by the wizard 7 4 5 Register Table size This wizard moves the tool head from edge to edge
83. 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 Job setup dialog 81 90 User Manual Kongsberg XP 7 9 2 2 Tool height calibration AN Knife blades are extremely sharp XP is equipped with an Automatic tool height calibration system Therefore the system will run without any manual height calibration If you for any reason would like to add an offset to the measured height use the Tool Height Calibration dialog Select the tool to be adjusted Press the Adjust active tool button to enter the wizard selection dialog Select Tool height calibration Follow the instructions given by the wizard step by step MAA A Repeat the procedure for all tools 7 9 2 3 Rotation adjustment for rotating tools AN Knife blades are extremely sharp 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 Wizard adjustment Select the tool to be adjusted Press the Adjust Active tool button to enter the wizard selection dialog Select Rotation adjustment Follow the instructions given by the wizard step by step u e UNH Repeat the procedure for all tools in the toolhead Manual adjustment Put an appropriate test material on the table and switch vacuum on From the Tool Configuration dialog
84. lator settings De 0 The compressed air is connected to a combined pressure regulator valve water trap The air pressure should be adjusted to minimum 6 bar 6 kg cm 6 10 Pa Recommended pressure level is 7 bar 7 kg cm 7 10 Pa O 24 User Manual Kongsberg XP 4 How to procedures 4 1 Introduction Keep away from moving parts during operation injury Before starting operation make sure that the table is free from obstructions no unauthorized personnel come close to the table Do not lean on racks guide ways or traverse during operation as this may cause personal All procedures for how to run the machine except Power on is based upon the following assumptions e The user interface is up and running e The actual tools are properly mounted and adjusted 4 2 Power on sequence Follow these steps to power up the system and get ready to work 4 2 1 Front End PC Switch on the PC and the monitor 4 2 2 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 4 2 3 XP Guide Use the mouse double click the icon for XP Guide Check that no error message indicates faulty conditions 4 2 4 Safety system Reset the Safety system by pressing the Stop pushbutton 4 2 5 Servo Power Press the Servo on pushbutton The Warning lamp on top of the Y carriage should be on without fl
85. le View are sorted in normal or reversed order The sorting is toggled by clicking the header of the columns The files are ranged the way they will be executed when Auto Open is activated A single click on a file will display the design in the Preview window When a file is opened that is selected as a job the design will be displayed in Job View LZ 3l Customize File View The Customize File View dialog is available from e Main Menu gt View gt Customize File View e File View gt Pop up menu 181 User Manual Kongsberg XP Customize file view Column 2 Column 3 Column 4 Column 5 Size x y MD ue s Flute p Z IEM 7 Material y Use the Customize File View dialog to define the kind of data which you want displayed in the columns in File View Customize the 4 columns by selecting the appropriate field in the drop down list The content of the different fields are File Header parameters in the Input File except from the Size which is calculated after the file has been opened 182 User Manual Kongsberg XP 12 4 File View toolbar You will find the following buttons in the File View toolbar Up one level 12 4 1 Shows file names and details Auto Open function Enable Move finished file mode Moves the current job when finished to a sub directory and removes it from the list of files in the File View Press the button a second time to di
86. m File view the first design will be located relative to the reference point as in single design layout The following designs will be placed according to the settings of the Job Layout Snap function If a design is opened using drag and drop it can dropped anywhere inside Job View The bar on top of Job View is showing the name of the selected design Note e By using the Multi Design functions you can locate your design anywhere inside the Job View area The red and green traffic light will show if the work is inside the work area boundaries or not e A combination of Multi Design and ARS is not supported 7 8 3 Multi design layout functions Note All functions described here are available from Main Menu gt Layout and from the Pop up menu in Job view 7 8 3 1 Select a design A selected design is always shown in pink After a design is opened it is always selected It can also be selected by clicking on a line in the design or holding the left mouse button down and drag a square over the designs to select 7 8 3 2 Select all designs All designs are selected with Ctrli A or by selecting Select All from the menus 85 User Manual Kongsberg XP 7 8 3 3 Delete selected designs Selected designs are deleted by pressing the Del key or by selecting Delete from the menus 7 8 3 4 Delete all designs All designs are deleted selecting the menu item Delete All 7 8 3 5 Rotate selected designs Selected designs ca
87. me tool and desired depth 4 When executing the job with this Job Setup file selected the multi pass function will be carried out for the specified logical tool s 5 The multi pass lines will be executed in the same sequence as they appear in the Job setup dialog This picture shows a Job Setup with double pass creasing with logical tool no 22 FT Job setup ll Job setup Board size Current job setup Depth unit Speed unit cam mill_job 1 v Open MM v im min v area eee Y y AD TY F v gt Extended wii too IX nE xY xY 2 Er Hi Drs ieee 21 4 HP Maing 1 5 6 00 8 00 40 2 00 60000 2 MN y HP Maing 1 gt 6 00 8 00 40 2 00 50000 2 HP Miling 1 1200 1200 800 40 200 50000 22 Y HP Miling 1 z 50 8 00 40 2 00 50000 2 B i Hemangi 1200 1200 800 4 200 5o00 More Test line 23 Y Laser pointer Ignore Circle adjustment 23 Knife before crease a A eo 33 User Manual Kongsberg XP 4 13 Jobs including reverse score Take care e Knife blades are extremely sharp e Keep away from all moving parts e Ensure all other personnel stays in a safe distance from all moving parts e Use hearing protectors A typical use of reverse score is when you want to add a crease line on the front side of a material that you normally prepare from the rear side Reverse score is available by modifications in the Job Setup file This function requires that the table is equipped with left and right rulers Proce
88. ment to the default width 8 8 9 V notch 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 115 User Manual Kongsberg XP 8 9 HD Knife Tool Knife blades are extremely sharp The HD knife tool mounted on a HDU 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 8 9 2 How to replace a knife blade This picture shows how the knife blade is aligned Use these two screws to fix release the against two alignment pins knife blade 116 User Manual Kongsberg XP 8 9 3 How to insert remove the HD knife tool 1 Turn the HD knife tool correctly to fit the 2 Insert the first latch pin alignment pin 3 Insert the cotter pin 4 Insert the second latch pin and cotter pin For this tool complete the following adjustments Lag setting The knife lag depends upon the blade adapter Nominal value is 10 mm Tool height Measured automatically possible to add an offset value Tool rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to laser pointer For more information about how to run the adjustment wizards see the Tool Configuration chapter 88 117 Use
89. milling underlay y The vacuum cleaner can be used for automatic W fr cleaning of the felt pi b Use the FaceMill exe to make a file that covers e nr 2 the actual area Set bit size to 65 mm 2 5 inch and set trim sizes to zero Hint Make a file name that reflect the size used Make a job setup file with low spindle speed zero depth and maximum feed Insert the dummy bit into the chuck and adjust tool so the brush is working properly 146 User Manual Kongsberg XP 8 12 The VibraCut knife tool AN Knife blades are extremely sharp 8 12 1 Description The VibraCut knife tool is available in two models VibraCut knife tool Running with 6000 RPM and amplitude 0 15 mm 0 006 inches this tool is recommended for light duty corrugated materials High Frequency VibraCut knife tool 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 e To reduce material tear a foot is available e The same set of knife adapters can be used 147 User Manual Kongsberg XP 8 12 2 Replace knife blade Remove the foot by pulling the foot straight out Loosen the screw A and replace the knife Ensure the knife has correct position relative to the screw Push the knife down while the screw is fixed 148 User Manual Kongsberg X
90. n be rotated with the functions Rotate 90 Rotate 180 or Rotate 7 8 3 6 Positioning selected designs with the mouse Selected designs can be positioned by holding the left mouse button down on a selected element and move the mouse They can be dropped anywhere or snapped to existing designs depending upon the Snap function settings 7 8 3 7 Positioning selected designs with the arrow keys Selected designs can be positioned with keyboard arrows and placed in the JobView depending upon the Snap function settings The step size is defined in Job Layout Setup gt Nudge 7 8 3 8 Step and repeat on selected designs In Multi Design layout Step and Repeat works on selected designs only 7 8 4 Job Layout Setup Job Layout setup is available from Main menu gt Layout or Ctrl L Layout Setup Snap On O Off Snap distance mm 7 8 4 1 Snap Gapbelweendesigns 9 o mm The snap function is turned on and off by ticking the radio buttons on and off Nudge Mudge mm 7 8 4 2 Snap distance 5 d asa 5 jm When the snap function is on a design will be snapped to another design if it is positioned closer than the snap distance 7 8 4 3 Gap between designs This parameter defines the distance between designs after a snap function is completed 86 User Manual Kongsberg XP 7 8 4 4 Nudge Fine positioning with the arrow keys on the keyboard 7 8 4 5 Nudge step Defines the step the design is moved with when pressing an arrow
91. n parking 8 11 5 Vibration monitoring HSMU Warning ay To protect the spindle a vibration monitoring system is implemented A warning will tell the user to reduce RPM If very high level occurs the machine will stop See HSMU precautions 127 Router vibration level too high reduce speed Cancel 124 User Manual Kongsberg XP 8 11 6 HPMU specific issues 8 11 6 1 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 8 11 6 2 Suction house adjustable height On HPMU you can lock the suction house in any height still it is allowed to move upwards NUL This function is useful in order to e Adapt to different material thicknesses Allow false air input in order to reduce suction force ff Y y IMA fi 8 11 6 3 RPM limitation Running 8 mm bits at a high RPM rate can generate vibrations and excessive wear Using bits with extended lengths at high RPM can also be dangerous Therefore using long 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 8 11 6 4 Chiller error codes If any chiller failure occurs look at the chiller display to see the real reason for the problem Se RO Reet ees le
92. ndle When replacing a spindle torque the motor clamp to 5 Nm 44 Ibf 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 8 11 8 11 Empty vacuum cleaner in time Do not leave the machine running if the vacuum mo cleaner can go full IN AN It This might cause damage ii H y 130 User Manual Kongsberg XP 8 11 9 HSMU HPMU routing advice 8 11 9 1 Milling bits Use bits with short cutting lengths for thin materials For best performance and minimum wear do not let the bit stick out more than necessary 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 ACM ENGRAV TOOL V90 MAX RPM ORDER NO 02731628 www esko com 131 8 11 9 2 Acrylic or Multi Purpose bits User Manual Kongsberg XP Bits with small cutting diameters 3 4 mm 0 12 0 16 in are more balanced than bits with larger cutting diameters and can be run with higher RPM normally 60 000 Use large diameter bits 5 6 mm 0 20 0 24 in when needed to get rid of the chips in thick materials Max RPM HSMU 40 000 Max RPM HPMU 60 000 Edges are brittle Never let bits touch each other or other hard surface Always store in proper container Acrylic bits A are polished extra sharp for Acrylic
93. ned as the Main Reference point The other fixed reference points 2 10 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 e A full working area e Correct sheet feed operation e Correct handling of long jobs Using the Main reference point during program execution ensures correct operation 67 User Manual Kongsberg XP 7 2 2 The Main Reference point for i cut For i cut to run properly the Main Reference point should be set in a specific position on the table using i cut reference point setting wizard 72 After i cut reference point setting do not modify the position of the Main Reference point If you need a reference point in another position on the table use one of the other reference points available 2 10 7 2 3 Rulers and reference points The ruler system ensures an easy and correct positioning of the material on the table Working area L_ Main reference point Se dr 10 mm 0 4 inches The Main Reference point shall be defined 10 mm inside the ruler When you use the lower 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 lower right ruler is normally used for reverse score operations At the same time the direction of the X axis is
94. nife Fuses are available on the Tool Board inside the actual tool Remove the plastic cover on the tool Remove fuse Fhr or Fu d check with ohm meter If blown replace with a new identical fuse Insert main power cable into the wall socket and turn main power ON For information about fuse sizes see table below 2 T2A125V NANO 42441618 Tool rotation T 4A 125V NANO 42444828 173 User Manual Kongsberg XP 10 7 HPMU Chiller fuse R Turn the fuse holder 90 deg Now you have easy access to the fuse 1 Spare fuse 2 Fuse in action Fuse T 1A 250V 5x20 mm 174 User Manual Kongsberg XP 10 8 HPMU Chiller heater fuse F 4A 250V T 5x20mm Slow Blow 42448944 175 User Manual Kongsberg XP 11 Appendices introduction The appendices section of this manual contains mainly reference information Much of this is available also in the context sensitive help included in XP Guide For that reason you will find this section in English language only 176 User Manual Kongsberg XP 12 Appendix The Graphical User Interface a el wag E CAL i A om 1 Ma md 6 We Ea i The XP Graphical User Interface GUI contains these main elements 1 Main Menu 5 Preview 2 Main Toolbar 6 Job View Toolbar 3 File View Toolbar 7 Job View 4 File View 8 ARS Toolbar 9 Status Bar 177 User Manual Kongsberg XP 12 1 The Main Menu The following functions are available fr
95. nst the left ruler Configure vacuum zones according to the material size Switch Vacuum on Ensure that you run with a suitable Program Reference point 10 Execute the job by pressing Start 11 To repeat the job press Init and repeat this procedure from point 6 30 4 9 OS CON AU User Manual Kongsberg XP Hard board production Take care e Milling bits are extremely sharp e Keep away from all moving parts e Ensure all other personnel stays in a safe distance from all moving parts e Use hearing protectors To prepare hard board materials the procedure is as follows 1 Mill through the top layer using HSMU HPMU 2 Cut through the mid section using the HF VibraCut knife tool 3 Mill through the bottom layer using HSMU HPMU Ensure that the tool configuration is correct for the job and corresponds with the Job Setup information Ensure that the router bit is sharp and proper for the job Ensure that the knife blade is sharp and proper for the job Ensure that the Job Setup information is correct for the material If not select Job Setup file From File View select the Input File Retrieve information about required sheet size from Job View Position a sheet of material against the left ruler Configure vacuum zones according to the material size Switch Vacuum on 10 Ensure that you run with a suitable Program Reference point 11 Execute the job by pressing Start 12 To repeat the job
96. nter the wizard selection dialog Select Center Offset Adjustment Follow the instructions given by the wizard step by step Manual adjustment See A AA Pp O 11 12 13 14 15 16 Put an appropriate test material on the table and switch on the vacuum From the Tool Configuration dialog select one tool Press the Adjust Active tool button to enter the wizard selection dialog Select Manual adjustment of center offset and angle Enter value for the Center offset and select Activate Note that the tool will move as the new value is activated Press Tool override down and Jog approximate 10 cm to make a test cut Press Tool override down once more to lift the tool again Press the Jog button for the return direction shortly just to turn the tool Press Tool override down once more to lower the tool again and Jog the same distance back Press Tool override down once more to lift the tool again Measure the distance between the two cuts As a guideline the distance should be 2 x material thickness If exact the Center offset is correct select Finish to exit If greater the Center offset value should be increased Repeat from point 5 If less the Center offset value should be decreased Repeat from point 5 92 User Manual Kongsberg XP 7 9 2 5 Manual adjustment of Center Offset and angle Sometimes it might be necessary to fine tune the adjustments obtained using the wizards Manual adjustmen
97. o indicate the centre of the picture The green circle indicates that high accuracy area If a register mark is detected outside this area the machine moves the camera centre over the register mark and takes a second picture This tab defines which camera to be used and also which camera that creates the Image The only time the operator needs to use this tab is when a new camera is installed 1 Misc This tab is used when entering the license code 1 1 For more information see Installation Guide for XP available on the XP Guide CD 44 User Manual Kongsberg XP 5 3 3 Other camera controls Camera info Live Video Snapshot Adjust offset Calibrate Camera Informational messages from the camera control Press this button to enable live video The camera picture will be continuously updated One single picture will be taken If a register mark is available in the picture it will be detected Run wizard in order to adjust the offset of the camera Run wizard to calibrate the camera 45 User Manual Kongsberg XP 5 3 4 Pre defined register marks ArtiosCAD When the position of the register marks is included in the Input file to XP Guide we call it pre defined register marks From ArtiosCAD a maximum of 4 pre defined register marks can be added to the design A description on how to generate register marks in ArtiosCAD is available from the document ServiceGuide_ArtiosCAD Kongsberg on
98. o the empty line Press the Apply button to save the new values Select the right board size from the Job View gt Board Size drop down list This will ensure a correct size of the displayed board in Job View 7 11 Change Flute grain direction The flute grain direction is altered from Ze e Main Menu gt Options gt Toggle Flute Direction Job View toolbar gt Toggle Flute Direction e Pop up dialog in Job View e Ctrl F Correct setting of flute grain direction is important in order to obtain correct cutting creasing depth 95 User Manual Kongsberg XP 7 12 Transformations The transformation dialog is available from e Main Menu gt Options gt Transformation e Ctri Alt T e Pop up dialog in Job view Transformation 7 12 1 Scaling X Y Enter a value in the edit box to scale the design A value less than 100 will decrease the size and a value greater than 100 will increase the size of the design Applies to current job only Use the Up down arrows to step the scaling in ye 100 steps of 10 Scaling Rotation el 4 100 sg 1100 Origin in lower left corner 7 12 2 Scaling X Scaling Y Enter a value in the edit boxes to perform differential scale of the design Note Unfortunately the picture in Job view does not show the design with differential scaling only common scaling But the result on the table is according to the input 7 12 3 Rotation Enter a r
99. ocedure Remove the main power plug from the wall socket as an extra precaution 0 Switch power off with the Main Power switch before starting the fuse before starting the fuse replacement procedure 10 1 MPU fuses Fuse location 115V 230V Line fuses F1 and F2 T 15A 250V 1 1 4 x 1 4 in T 6 25A 250V 1 1 4 x 1 4 in 6 3 x 32 mm 6 3 x 32 mm 200V Servo power fuse F200 T 15A 250V 1 1 4 x 1 4 in T 15A 250V 1 1 4 x 1 4 in 6 3 x 32 mm 6 3 x 32 mm 48V Servo power fuse F48 T 8A 250V 1 1 4 x 1 4 in T 8A 250V 1 1 4 x 1 4 in 6 3 x 32 mm 6 3 x 32 mm 24V fuse F4 T 6 25A 250V 1 1 4 x 1 4 in T 6 25A 250V 1 1 4 x 1 4 in 6 3 x 32 mm 6 3 x 32 mm All fuses are located on the rear side of the Main Power Unit MPU F24 F48 F200 Q Line fuse we P5mp P200mp 00 YOY y Fuse replacement procedure 1 Remove base cover in front of MPU 2 Remove one fuse check with ohm meter if blown replace with a new identical fuse Repeat for each fuse 3 Replace base cover 4 Insert main power cable into the wall socket and turn main power ON o elo 3 O 168 10 2 X1 fuse cerro 1 8 24A AC amplifier X1 2 SCU unit User Manual Kongsberg XP Remove X1 cover Remove cover from AC amplifier unit Check fuses F2 F5 with ohm meter If blown replace with a new identical fuse Replace covers Insert main power cable into the wall socket and turn main power ON Fuse T 10A 250V
100. of the table in order to measure the table size This registration is normally done just once Procedure Press the Register Table Size button Follow the instruction given by the wizard 72 User Manual Kongsberg XP 7 4 6 Adjust X1 to X2 angle Use this wizard to obtain correct angle between X axis and Y axis Procedure Press the Adjust X1 to X2 angle button Follow the instructions exactly as given by the wizard i f B y Note Use drilled holes in table as reference see picture LL er 7 4 7 Calibrate foot on the measuring station Use this wizard to calibrate the height level of the measuring station Procedure Press the Calibrate foot button Follow the instruction given by the wizard Repeat this procedure after maintenance on the traverse carriage or measuring station 7 4 8 Adjust measuring station position Use this wizard to calibrate the position of the measuring station to the system Procedure Press the Adjust measuring station position button Follow the instruction given by the wizard Repeat this procedure after maintenance on the measuring station 7 4 9 Vacuum control For details about this function see separate chapter Vacuum control 100 7 4 10 Conveyor belt control Split sheet feed The sheet feed movement is divided into two sequences Sheet feed correction Adjust the movement of the conveyor belt to be shorter or longer 73 User Manual Kongsberg
101. ogue and select a Job Setup file from the 7 drop down list in the dialogue 78 User Manual Kongsberg XP 7 7 3 Create and edit Job Setup files Job Setup is maintained from the Job Setup dialogue The Job Setup dialogue is available from e Main Menu gt Options gt Job Setup 4 e The Job View tool bar button e Pop up menu in Job View e Ctrl J Job setup le Job setup Board size Current job setup Depth unit Speed unit cam mill_job 1 v Open MM v m min a Ca V gt fas Ty F v gt Extended Line Tool PES A xY XY iz en 01 Ly atende 2 E fe HP Miling 1 60 8 00 40 200 60000 22 E i tir mang m 6 00 8 00 40 200 50000 2 HP Miling 1 lt 1200 1200 800 40 200 50000 22M emin z 6 00 6 00 800 40 200 50000 2s HP Miling 1 1200 1200 800 40 200 50000 More Testline 23 Laser pointer Ignore 22 Circle stment 23 Knife before crease l Job Setup is edited line by line The parameters are described below When finished editing use the Apply function to save to current or to a new file name Each line in Job Setup can be tested using the Test Line function Follow the instructions in the dialog SA 7 7 4 Job Setup Parameters 7 7 4 1 Depth unit Specify if the depth unit is mm inch or percentage 7 7 4 2 Speed unit Specify if the speed unit is mm min ips or percentage 79 User Manual Kongsberg XP 7
102. ol buttons available Using the cross in upper right corner is not recommended and the consequence is un predictable OK Apply Cancel Help OK User Manual Kongsberg XP 2 Safety regulations 2 1 Introduction The Kongsberg table is designed to conform to safety regulation standards Nevertheless operating the table can involve hazards if the operator does not follow the operating instructions or uses the table for non intended purposes The safety regulations described below are supplemented with safety warnings in the respective topics 2 2 Responsibilities 2 2 1 The manufacturer The manufacturer is responsible for delivering the system according to safety regulation standards 2 2 2 The customer The customer is responsible for Ensuring that the system is used for it s intended use only Allowing that only authorized and trained personnel operate the system Preventive maintenance as described in the Maintenance manual The local regulations regarding installation and operation are fulfilled 2 2 3 The operators The operators are responsible for e Operating the system only when it is in a flawless state e Ensuring that no unauthorized persons come close to the system 2 3 Requirements to be met by operators The personnel operating the system must e Be adequately trained e Have read and understood the instructions described in Safety regulation as well as any other safety warnings 2 4 Definition of use
103. om Main Menu and sub menus 12 1 1 File Open Create a box Exit 12 1 2 View Position Display View Messages Customize File View View Finished Jobs Tool bars Status Bar 12 1 3 Options Tool configuration Job Setup Board Size setup Toggle Flute Direction Transformation Step and Repeat Counter setup System Option Table Options Registration setup Open an Input File 66 Work with 123Box 59 Terminate XP Guide Display of table positions and parameters 189 Message Display provides a log of system messages 188 File View configuration 181 List finished jobs when running in Auto Open mode 183 Configure GUI tool bars Configure Status Bar 187 Tool configuration and adjustments 88 Select and edit job setup files 78 Edit table of available board sizes 95 Specify actual flute grain direction to the system 95 Specify scale and rotation 96 Specify multiple copies of current job 98 Parameter setting for crease using a matrix 99 For folding carton only Enter the System Option dialog 74 Enter the Table setup dialog 71 Configure the ARS system 103 178 User Manual Kongsberg XP 12 1 4 Layout Toggle Layout Mode Layout setup Delete Delete Al Select Al Rotate 90 Rotate 180 Rotate Rotates selected design a user defined angle 85 12 1 5 Help About XP Guide XP Guide version information Information about maintenance intervals You will
104. otation degree value in the edit box to rotate the design See table on next page for simple rotation angle calculation Use the Up down arrows to step the rotation in steps of 90 degrees Example A value of 90 will rotate the design 90 degrees in counter clock wise direction You can enter both and values 7 12 4 Current Job Only Check this box to make these transformations valid for the current selected input file only 96 User Manual Kongsberg XP 7 12 5 Rotation angle calculation Y Use the table below to calculate the Bi angle from a simple measurement In a distance L from the lower left corner measure the deviation from the horizontal line d Find the corresponding d value in the table below and read the angle v in degrees L 1 m 40 inches im cin com in 0 an 0 aa 0 029 1 146 1 64 0 022 _ 21 32 0 940 es pons po uasi HE 15 oos6s 22 1 260 14 16 0 090 _ 23 32 1 029 2 ous5 23 1 318 3 32 0134 3 4 1 074 3 oaz 24 1375 1 8 0o179 25 32 1 119 4 oz 9 25 1432 5 32 0224 13 16 1 164 5 o2zs6s 26 1 489 3 16 0 269 27 32 1 208 6 0344 27 1 547 7 322 o313 7 8 7 0401 28 1 604 1 4 0 358 29 32 1 298 8s jo4ss8s 29 161 9 32 0 403 _ if 15 16 1 343 9 oss 30 1 718 5 6 0448 31 32 1 387 lio 0573 31
105. oth models are covered by this chapter 8 11 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 router bit cooling and to ease chip removal Adjust for proper operation There is also an air blow inside the spindle but no user adjustment is necessary 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 empty over time 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 Note When in lower position the house should be free to move up down Therefore the house should never be locked when in lower position HSMU 122 User Manual Kongsberg XP 1 Router bit Shaft diameter is 6 mm HSMU and 6 8 mm HPMU 2 Chuck The HSMU HPMU is equipped with one 6 mm chuck on delivery 3 Spindle 8 11 3 Tool head mounting The HSMU HPMU tool head is mounted onto the Z1 carriage in the same way gt 123 User Manual Kongsberg XP 8 11 4 Tool head park position Use the HSMU HPMU park position for safe tool head storage Note For safety reasons always use a dummy bit whe
106. ou can not move the chuck with the chuck tool another 10 mm 12 mm for HPMU key might be used together with a bit to unscrew the chuck This procedure might be necessary if a bit is stuck Apply the taper brush to clean the taper 138 User Manual Kongsberg XP Push the air clean button to help remove contamination 149 III jj Y y AMA Ti Clean the chuck Apply small quantities of grease to the threads of the chuck when necessary Avoid the clamping area Do not use oil as it could enter the clamping area and reduce the clamping force Also apply small quantities of grease to the outer cone of the chuck Torque up the chuck by hand using the chuck tool and a dummy bit Maximum torque 2 Nm 18 Ibf in Hold the rotor with the 13 17 mm key 139 User Manual Kongsberg XP Close the chuck on a dummy bit Chuck maintenance kits are available on the Esko web shop www esko com 140 User Manual Kongsberg XP 8 11 12 HSMU HPMU bit length and position d 4 gt Keep distance d small gt 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 Go For proper clamping keep distance e 20 mm 0 8 inch as a minimum ja To achieve material through cut the distance d must be at lea
107. phical User Interface GUI This part is available as context sensitive help from the XP Guide program In addition it is available as Appendix A in this manual Typical tasks are described in detail What do I have to prepare before the start of a job This is a part of the How to chapter The Automatic Registration System is covered by a separate chapter A description of all parameters to be set and how to set them A complete description of the XP tooling system What maintenance is required in a short and long term Some definitions used in this document Name or style This is the dialog that appears when you click the Right mouse Pop up dialog Buton g pp y 9 Start 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 XP Guide user interface Options gt System Option Menu selection From the Options menu select System Option 123 is the page number where the actual function is described It is 123 also a hyperlink a mouse click on the number will bring you directly to the issue User Manual Kongsberg XP 1 1 Local languages This manual is available in a wide range of local languages When the document is translated into a local language the screen pictures some illustrations and the content in the Appendices remains in English language 1 2 About XP Guide dialogs x To exit from any XP Guide dialog use the contr
108. press Init and repeat this procedure from point 6 31 User Manual Kongsberg XP 4 10 Cutting thick materials Take care e Keep away from all moving parts e Ensure all other personnel stays in a safe distance from all moving parts e Use hearing protectors When preparing materials with thickness between 45 50 mm 1 2 in the following rules apply No camera operations are available Disable Measure material thickness In Job setup use T function to specify the cutting depth This function is for knife tools only More job setup Job setup Job setup Board size Knife overcut Current job setup Depth unit Speed unt Enable knife overcut y N i ete gt al A Start Line Tool E vs ae 12 LE UY Extended p 1 3 Foamknie1 100 100 100 A lt rl tl FoamKnife 1 100 100 100 mam W No tool W No tool Material measurement al W No tool More Test line 1 C No tool Ignore Circle adjustment 1 C Knife before crease Disable Material thickness measurement Job setup gt More Cutting depth using T function Note This function is useful for all materials with an un even surface Help 4 11 Make a pen plot Take care e Keep away from all moving parts e Ensure all other personnel stays in a safe distance from all moving parts e Use hearing protectors 1 Ensure that the tool configuration is correct for the job and corresponds with the Job Setup informat
109. r Manual Kongsberg XP 8 10 Foam Knife Tool AN Knife blades are extremely sharp Please note Be careful where to place the tool head when not in use If the tool head is left down on a table surface the knife might be exposed as the material hold down wheels moves up A 8 10 1 Tool head mounting The Foam knife tool head is mounted onto the Z1 carriage in Kongsberg the same way as the other Z1 tool heads ESKO artwork For this tool complete the following adjustments Lag setting The knife lag depends upon the blade adapter Nominal value is 3 5 mm Tool height Measured automatically possible to add an offset value Tool rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to laser pointer For more information about how to run the adjustment wizards see the Tool Configuration chapter 88 118 User Manual Kongsberg XP 8 10 2 How to replace a knife blade Loosen the fixing screw replace the knife blade and fix it again No additional adjustments are necessary as the tool height is measured automatically 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 8 10 3 How to replace the knife adapter Loosen the fixing screw replace the adapter and fix it again No additional adjustments are necessar
110. r pressure when running at full Pressure speed Note B The maximum Speed Dependent Pressure is 200 A 155 8 15 4 Foot solution User Manual 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 the clamp C as indicated to lock the knife shaft 2 Turn the screw S to adjust the cutting depth When seen from the knife side a clockwise adjustment will increase the cutting depth 156 User Manual Kongsberg XP 8 16 RotaCut knife tool AN Knife blades are extremely sharp 8 16 1 Description The RotaCut knife tool 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 e Itis not suitable for curves with small diameter e Itis not suitable for designs containing short lines in combination with sharp angles The RotaCut knife tool is prepared for Decagonal knife blades 225 mm 1 inch 157 User Manual Kongsberg XP 8 16 2 Tool adjustment The RotaCut knife tool is adjusted in the same way as the other XP tools regarding rotation angle and offset but tool height in manually adjusted Tool height calibration for Rotating knife Tool position 2 Tool height Height settings Tool height for RotaCut
111. r the V notch knife we recommend the manual procedures for tool rotation and centre offset adjustment e When adjusting tool rotation and centre offset use a thin folded carton material e Remember that you should look at the bottom side of the material for correct alignment e 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 Lag setting The knife lag depends upon the blade adapter Nominal value is 0 7 mm Tool height Measured automatically possible to add an offset value Tool rotation Adjust tool angle tangential to moving direction Center Offset Adjust tool sideways until centered Tool Offset Adjust offset relative to laser pointer For more information about how to run the adjustment wizards see the Tool Configuration chapter 88 114 User Manual Kongsberg XP 8 8 6 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 Define the depth of the V notch cut in the Option Job Setup CTRL J 3 Normally the cut should extend down to just above the bottom liner closest 8 8 7 How to set the width of the V notch cut Enter Job Setup More V Notch to make adjustment to the default width 8 8 8 How to run the 4 cut function Enter Job Setup More V Notch to make adjust
112. rdinate System The Table Zero Mode is automatically selected at Start Up The button remains lit until the Zero Position is reached If Forced tool height measuring mode is enabled this button will start a Tool height measuring sequence For more information see 38 3 4 7 Servo On Off e Press this button to switch the Servo on off The servo power is on when the lamp is lit 3 4 8 Jog buttons Press the Jog buttons to move the tool head in the desired direction S a lt e The system must be in Stop mode e the Stop button must be lit for M these buttons to be operative Note It is possible to configure the jog direction see Option System setup 21 User Manual Kongsberg XP 3 4 9 Continuous Jog Press a Jog button to manually move the tool head with constant speed The X and Y Jog buttons can be operated both individually and simultaneously Press the single arrow for low jog speed Press both symbols for medium jog speed 3 4 10 Incremental Jog Forced tool height measure Press this button to select the Incremental jog Forced tool height measuring mode Press the button a second time to disable the Incremental jog Forced tool height measuring mode For information about Forced tool height measure see 38 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
113. reversed Working area 68 User Manual Kongsberg XP 7 3 Speed Setup The Speed setup dialog is available from e Main Menu gt Options gt System Option e CTRL AIt O Select the Speed Setup tab 7 3 1 Table Acceleration The Table Acceleration can be reduced to a value of the maximum acceleration Enter the wanted value in the Acceleration edit box Option bd Speed setup Table System Display color Acceleration Panel settings Jog speed Incr Jog mm Jog panel direction 0 degrees 5td L s 7 3 2 Continuous Jog speed The Continuous Jog speed can be reduced to a value of the maximum jog speed Enter the wanted value in the low Jog Speed edit box Enter the wanted value in the high Jog Speed edit box 69 User Manual Kongsberg XP 7 3 3 Incremental Jog The size of the Incremental Jog movements can be customized Enter the wanted value in the short Jog Increment edit box Enter the wanted value in the long Jog Increment edit box 7 3 4 Jog directions E degrees Std L Specify jog direction for the Manual Jog buttons on the Operator panel 70 User Manual Kongsberg XP 7 4 Table setup The Table setup dialog is available from e Main Menu gt Options gt Table Option e CTRL R The following selections are available 7 4 1 Set Reference point Speed setup Table System Display color Table reference The Set Reference point wizard is an ai
114. sable the Move finished file mode Note You can view finished job by selecting View gt View Finished Jobs on the menu or by selecting View finished job from the pop up menu in the file view Auto Open function Pressing this button activates the Auto Open function The file at the top of the File View list will automatically be opened as a new job when the current job is finished Press the button a second time to disable the Auto Open function Note It is a pre requisite for this function that the Move finished file mode is enabled When the Move finished file button shows this face it indicates that the Move finished file mode is disabled no automation 183 User Manual Kongsberg XP 12 5 The Job View File Material Sizelix wy Due Flute EF MAPCUT ACM 125 61 Y When you open a file the design is displayed in the Job View window Designs placed in Job View can be manipulated according to the selected layout mode Various display options are available from the Job View toolbar The File Information Bar on top of Job View display some parameters regarding the last Input File opened 184 User Manual Kongsberg XP 12 6 Job View toolbar A 811 mamo i 6944 1635 mm O Show job view in full screen When in full screen display the button face changes to this Show job view in split screen Enters zoom mode The cursor changes to a magnifying glass Select area to
115. setting is available in the Table setup dialog Manual Control Miss pump 2 Enable 2 vacuum pumps e Select if pump 1 or pump 2 or both should start when Vacuum 0 Timeout after job sec on is pressed e If both are selected start of the second pump will be delayed 101 User Manual Kongsberg XP 7 15 5 Vacuum section selection Press Vacuum Section Selection button to enter the Vacuum Section Selection dialog Vacuum Control From this dialog you prepare a suitable vacuum area on the table by selecting vacuum sections The numbers correspond to the Cutting Table as shown Y ARGS in the picture below Press a button once to enable a section push the button a second time to disable UD 0 PA Es Note The vacuum section configuration depends upon the actual delivery Only one max configuration is shown here 102 User Manual Kongsberg XP 103 User Manual Kongsberg XP 8 Tooling system introduction Laser radiation Do not stare into beam The tool head is equipped with a class II laser pointer Emitted laser power lt 1 mW Knife blades are extremely sharp Therefore take care when handling knife tools 8 1 Tool handling and care All tools are precision instruments and should be treated as such to ensure proper operation Take special care when e Tools are inserted or removed from their stations No excessive force should be applied e Tools should
116. st 18 mm 0 7 inch f Balanced bits dl 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 141 User Manual Kongsberg XP 8 11 13 HSMU HPMU Tool adjustment 8 11 13 1 Adjustments for the standard tool positions For this tool complete the following adjustments e Tool height Measured automatically possible to add an offset value e Tool Offset Adjust offset relative to laser pointer For more information about how to run the adjustment wizards see the Tool Configuration chapter 88 Notes regarding Tool height adjustment When properly adjusted the router bit should barely touch the top surface of the material Notes regarding Tool offset adjustment Before executing the wizard for tool offset adjustment the Job setup file has to be prepared as follows Job setup Job setup Board size Current job setup Depth unit gt Speed unit Oper m m min Line Tool fai ice Lead Extended g H5_Milling O ln i 1 00 T a Q RotPosPen 299 gt x Mo tool E HS Milling 2 00 100 4000 More Test line 24 E 2 et E veo a oI D In the first line in Job setup specify HS milling tool with parameters as illustrated Then execute the wizard for tool offset adjustment 142 User Manual Kongsberg XP 8 11 14 HSMU HPMU Job setup Job setup
117. t for RM Knife RM_Knife 1 Tool position 2 Angular offset l l Move the tool holder in one direction by using the jog buttons on the operator Use this dialog to modify the panel adjustment values for angle and center offset 1 Select the tool to be adjusted 2 Press the Manual Check that the tool tip is approximately tangential to the direction of movement adjustment of button to enter the adjustment dialog If not adjust the angle offset below 180 deg 3 Key in or use the up down arrows to specify the 0 00 4 aoe wanted offset 4 Press Activate to enter the If the angular offset is approximately correct you might press Next to value save parameter and continue 5 Test the new settings Center offset Adjustment value for the centre offset mm ME If both center offset and angle are acceptable click Finish Note All XP tools should by default be close to correct angle when the adjustment value is 0 The Manual adjustment of function is useful if you want to test a tool for correct behavior before program execution 7 9 2 6 Offset adjustment Select the tool to be adjusted Press the Adjust Active tool button to enter the wizard selection dialog Select Offset Adjustment Follow the instructions given by the wizard step by step Repeat the procedure for all tools in the tool head oh E 7 9 3 More The More button opens the More dialog which contains selections to ignore del
118. that is one Y column of jobs will be filled up before a new one is established 7 13 2 2 XxY enabled You specify the number of copies in the X and Y edit boxes The total number of copies will be X x Y The job will be distributed in X columns and Y rows regardless the size of the board The Execute one at a time checkbox determines whether each copy should be completed before moving on to the next Alternatively all crease operations for all copies are completed before moving on to knife operations and so on Note If Sequencing is disabled job execution will be as Execute one at a time 98 User Manual Kongsberg XP 7 14 Counter setup dialog This function is available when Application is set to Folding Carton from La e File View toolbar gt Matrix e Options gt Counter setup The Counter function is used when the job is executed on top of a matrix The purpose of this function is to avoid cutting Counter thickness mm through the matrix Counter setup Automatic minimum value 0 00 2 Fixed value Counter function enabled 7 14 1 Counter thickness Automatic minimum value Used when the thickness of the matrix and the material to be cut is equal The thickness of the matrix and the material will be measured The cutting depth is set to the half of the measured value If the matrix thickness in this manner becomes less than the minimum value specified the value specified will be used
119. ton If no job is started within 30 min after the vacuum is switched on the vacuum pump is switched off automatically E se A job is started The vacuum pump will be started automatically C The job is finished The vacuum pump is switched off a time Timeout after the job is finished The time is entered in the Vacuum control dialog shown above 100 User Manual Kongsberg XP 7 15 2 1 Vacuum quick release mode option a Enable the vacuum quick release mode by pressing the Vacuum release push i button The function is enabled when the button lamp is lit If you are in the Vacuum quick release mode and the vacuum is switched off using the Vacuum on push button a valve will open to allow a quick release of vacuum inside the cutting table When vacuum is switched on again the valve will close 7 15 3 i cut vacuum control Pressing the Vacuum on pushbutton will start the vacuum pump Pressing the button a second time will stop the pump Pressing the Vacuum release pushbutton on the Operator panel will open the vacuum valve to allow quick release of the vacuum inside the cutting table Pressing the button a second time will close the valve and provide vacuum on the table as long as the pump is running Note When running i cut the cut vacuum control should be enabled 7 15 4 XP using two vacuum pumps as If your XP is equipped with two vacuum pumps option a pump El ccoo ss healer enable disable
120. uction valve according to the maintenance section 128 User Manual Kongsberg XP 8 11 8 7 Maintain bit clamping e Un proper clamping may cause the bit to slip in the chuck and damage to the table top ee ee ee 1 Keep the bit shafts clean Avoid greasy fingers Clean the bit shafts with acetone if OO O necessary but use only dry cotton tips on the chuck 2 Maintain air supply pressure of 7 bar Follow procedures for Chuck change and clean strictly 8 11 8 8 Operation at low and high temperatures Never run a spindle when ambient temperature is below 10 C 50 F Continuous operation at temperatures above 30 C 86 F is not recommended HSMU HPMU spindle is water cooled thus the ambient temperature is not that critical for the spindle itself aw ez imi l Le 8 11 8 9 Long term storage A More than 4 weeks storage of a spindle or a NW DDD HSMU HPMU requires e Turn the spindle by hand about 20 turn every 4 weeks e Spindle must be stored horizontally 129 User Manual Kongsberg XP 8 11 8 10 Consider having a replacement spindle lt The service interval will depend on the type of il Pa operation and is difficult to predict Indication of ad worn bearings may be increasing noise increasing wa vibrations or decreasing surface finish y p y a Note AS If the HSMU HPMU is used in regular production it is recommended to have a replacement spi
121. ustment dialog press Close Switch Vacuum off Now the camera offset is properly adjusted 57 User Manual Kongsberg XP 5 6 Verify correct offset adjustment 5 6 1 Draw the test figure Select No registration Option gt Registration setup Alt R gt No registration 2 6 _ Jog to a start position laser pointer in the X Y corner of the sheet 8 Press Start to draw the file S 5 6 2 Draw the test figure using registration marks Select Register mark input from input file and Camera detection Option gt Registration setup Alt R gt From input file Option gt Registration setup Alt R gt Camera detection Registration setup Registering tool Transformation No registration gt ffset and rotation only Register mark input Different X Y scale Ss A Camera operation Workfiow Automatic Hep SSS 2 Open the file regtest acm using the same Job setup pen tool for line 1 2 and 5 3 Move the machine to approximate the same position as used when the test figure was prepared and press Init Press Start The program will automatically read 4 registration marks and execute the file Inspect the final result Requirement The angles prepared by this file should be positioned exactly on the two registration marks prepared by the first file 58 User Manual Kongsberg XP 6 Work with 123Box 6 1 Introduction 123Box is an add on to the XP Guide control software for Kongsberg cutting tables
122. ve 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 corrugated material 5 6 mm 0 2 inch when executing the adjustments Before any adjustment complete a Table Top Reference function 7 9 2 1 Lag settings for rotating tools 1 Select the tool to be adjusted 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 90 5 Repeat the procedure for all rotating tools 89 User Manual Kongsberg XP Lag setting dialog Lag Setting Lag test see next picture Lag lag value This is the distance from the rotation center to the back of the knife blade Enter the value as measured or as found using the Lag test Width knife bottom width Laglrm Enter the measured knife bottom width New 0 1018 Current 0 10 2 Weidth mm 010 F Press Finish to save new lag settings Lag test an Run this Izaro to obtain cone lag value Press Start to execute the test figure once Follow the instructions in the dialog Add the measured value to the displayed value 2 Measure the distance marked with red on your test cut This distance shall be used as the L4G value 0 10 lt Cancel Circle lag Circle quality
123. w black tape indicates the warning area This area is restricted to operators and other trained personnel 2 5 Warning lamp on top of Y carriage Light is Off Servo power is off Servo power is on Safety system is enabled table is in operation Blinking Safety system is activated Reset Safety system to continue operation 2 7 6 DynaGuard Safety System The Photocell safety system consists of two light beams in front of the traverse and two behind In addition there is a stop mechanism mounted on each end of the traverse Machine movement will stop and servo power will be switched off if e One of the light beams is broken e The stop mechanism is activated for instance when a person is standing too near the table To continue operation after the Safety system has been activated do e Reset the Safety system by pressing Stop on Operators panel e Press Start to continue operation 14 User Manual Kongsberg XP 2 8 Protective equipment For the operator s Esko recommends the following protective equipment e Close fitting clothes to avoid being caught by the beam or the tool head which can cause injuries e Gloves to protect against cuts from materials with sharp edges Eye protection should be used by any personnel working with HSMU HPMU on XP e 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
124. wood etc Multi Purpose bits MP have a higher wear resistance and are suitable for aluface plastics MDF plywood wood etc MP bits can be identified by a small tooth at the tip 132 User Manual Kongsberg XP 8 11 9 3 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 8 11 9 4 Number of passes in thick materials The number of passes depends on material type thickness and bit diameter Use a pass depth that makes the groove free of chips normally that is a depth equal to the cutting diameter 8 11 9 5 Material hold down Material hold down may be a limiting factor Especially parts cut loose can be a problem if they are small This can be done to improve the situation e Use bits with smaller cutting diameter e Cover unused table area e Use wash out functions instead of cutting loose small waste parts 8 11 9 6 Mill
125. ximum allowed arrow height A when straight lines are converted to circles Maximum allowed arrow height value is 0 2 mm 0 08 inch SS DS Ns x gt NA N A 7 9 14 Vacuum setup Pressing the Vacuum Setup button opens up a new dialog where the vacuum section configuration for the actual machine is specified This setup is a one time job as long as the vacuum section solution on the machine remains un changed The setup should correspond to the actual hardware The selected setup will determine which vacuum section configuration that will be available in the user interface 7 9 15 Router setup From the Router Setup dialog the physical COM port used for communication with the Milling Unit HSMU HPMU is specified Router Setup Router COM e Note The inverter needs to be connected to a genuine COM Changing COM port requires restart of computer port If connected to a USB to COM adapter the communication will fail Cancel 76 User Manual Kongsberg XP 7 5 16 Park position Pressing the Park Position button opens the Set Park Position dialog offering the following functions Park position The park position is specified in the CAD system and transferred to XL via the from file input file Go to reference Move to the selected reference point after job finished point after job Selectable Enter co ordinates X Y for the park position The co ordinates are relative to park position the s
126. y 8 21 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 Operators panel will switch the laser pointer on again 164 User Manual Kongsberg XP 9 Maintenance 9 1 General Warning The main power should be switched off before cleaning is carried out More detailed information about XP maintenance is available in the Maintenance Manual for Kongsberg XP 9 2 Daily maintenance Inspect e Inspect the equipment in order to prevent any irregularities Clean e The table surface should be kept clean at all times For cleaning use iso propyl alcohol or white spirit e The room should be cleaned regularly Keep the cables free from grease floor vax etc e Use a vacuum cleaner to keep the inside of the conveyor belt clean 9 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 Photo cells The surface of the transmitter and receiver should be carefully cleaned using light soap and clean water Air pressure reduction valve The
127. y as the tool height is measured automatically 119 User Manual Kongsberg XP 8 10 4 Disable material thickness measurement More job setup Ed Set from Job setup gt More Ende overcut C Enable knife overcut For the Foam Knife tool the Disable material thickness measurement function is available Use this function if e Your foam material is too soft for the measuring C Run reciprocating nu in system e The surface of your material is un even Milling Tool Wat before movement starts 0 Matenal measurement E Disable material thickness measurement When the Disable material thickness measurement function is enabled the following rules applies e In Job setup the T function must be used for depth settings e In Job setup the Depths unit must be set to mm inches Percent not allowed e During tool up movements the knife is lifted to its top position 120 User Manual Kongsberg XP 8 10 5 Cutting quality To obtain best quality when cutting details as small circles we recommend e Reduce the cutting speed from Job setup e Cut in two or three passes each pass going a step deeper Multi pass 33 121 User Manual Kongsberg XP 8 11 HSMU HPMU AN Router bits are extremely sharp Use Eye protection to prevent accidents caused by breaking milling bit or small pieces of processed material 8 11 1 Introduction Two different milling tool heads are available HSMU and HPMU B

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