XN running i-cut Production

Console

User Manual

02 - 2016 | XN
 XN running i-cut Production Console

Contents
1. Preface.............................................................................................................................................................................................. 7

2. Change Record............................................................................................................................................................................. 8

3. Welcome...........................................................................................................................................................................................9

4. Using this manual..................................................................................................................................................................... 10

4.1 Main Sections...................................................................................................................................................................10
4.2 Name Styles and Symbols..........................................................................................................................................11
4.3 Pictures and Illustrations..............................................................................................................................................11
4.4 Local Languages............................................................................................................................................................. 12

5. Safety Regulations....................................................................................................................................................................13
5.1 Introduction........................................................................................................................................................................13
5.2 Responsibilities................................................................................................................................................................ 13
5.2.1 The Manufacturer............................................................................................................................................... 13
5.2.2 The Customer...................................................................................................................................................... 13
5.2.3 The Operators......................................................................................................................................................13
5.3 Requirements to be met by operators................................................................................................................... 14
5.4 Definition of use.............................................................................................................................................................. 14
5.5 Danger Zones................................................................................................................................................................... 15
5.5.1 Danger Zones...................................................................................................................................................... 15
5.5.2 Moving Parts, Laser Radiation and High Voltage..................................................................................15
5.5.3 Loose Clothing.................................................................................................................................................... 16
5.5.4 Noise Level........................................................................................................................................................... 16
5.5.5 Ejection of Parts................................................................................................................................................. 16
5.6 Warning Sign Explanation........................................................................................................................................... 16
5.7 Safety devices.................................................................................................................................................................. 18
5.7.1 Overview.................................................................................................................................................................18
5.7.2 Emergency Stop Button.................................................................................................................................. 19
5.7.3 Warning Lamp on top of Y Carriage.......................................................................................................... 19
5.7.4 DynaGuard Safety System............................................................................................................................. 19
5.8 Protective equipment.....................................................................................................................................................20
5.9 Procedures in case of malfunctions........................................................................................................................21
5.10 Residual Risk, XN.........................................................................................................................................................21

6. System Description.................................................................................................................................................................. 23
6.1 Naming conventions...................................................................................................................................................... 23
6.2 Main Power Switch........................................................................................................................................................ 24
6.3 Operators Panel...............................................................................................................................................................24
6.4 Variable Blow Back........................................................................................................................................................ 26

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6.5 Pressurized Air system................................................................................................................................................. 27

6.6 Application programs available................................................................................................................................. 28

7. Basic Operations....................................................................................................................................................................... 29
7.1 Power On Sequence..................................................................................................................................................... 29
7.2 Reset Safety System..................................................................................................................................................... 30
7.3 Power Off Sequence..................................................................................................................................................... 30
7.4 Continue after Safety Break....................................................................................................................................... 30

8. Prepare for a Job......................................................................................................................................................................32

8.1 Introduction........................................................................................................................................................................32
8.2 Create Job......................................................................................................................................................................... 32
8.3 Layer Setup....................................................................................................................................................................... 32
8.4 Production Setup............................................................................................................................................................ 33
8.5 Speed Setting...................................................................................................................................................................33
8.6 Flute/Grain Direction...................................................................................................................................................... 33
8.7 Vacuum Zone Selection............................................................................................................................................... 33
8.8 Job Execution...................................................................................................................................................................34
8.9 Milling Production........................................................................................................................................................... 34
8.10 Make a Pen Plot...........................................................................................................................................................35
8.11 Work with X-Pad...........................................................................................................................................................35

9. How To Procedures, Advanced.......................................................................................................................................... 38

9.1 Cutting Thick Materials.................................................................................................................................................38
9.2 Hard Board Production.................................................................................................................................................38
9.3 Multi Pass Milling............................................................................................................................................................39
9.4 Jobs including Reverse Operation...........................................................................................................................39
9.5 Work with different Reference Point Settings......................................................................................................40
9.6 MultiZone Production.................................................................................................................................................... 40

10. System Setup........................................................................................................................................................................... 42

10.1 Introduction..................................................................................................................................................................... 42
10.2 Adjust X1 to X2 Angle................................................................................................................................................43
10.3 Register Table Size...................................................................................................................................................... 43
10.4 Set Ruler Position........................................................................................................................................................ 44
10.5 Set Main Reference Point......................................................................................................................................... 44
10.6 Map Table Top Surface..............................................................................................................................................45
10.7 Reference Points and Coordinate System......................................................................................................... 45
10.8 Table Speed.................................................................................................................................................................... 47
10.9 Table Acceleration........................................................................................................................................................ 48
10.10 Jog Settings................................................................................................................................................................. 48
10.11 Set Table Top Reference.........................................................................................................................................48
10.12 Vacuum Setup............................................................................................................................................................. 49
10.12.1 Vacuum Section Configuration................................................................................................................ 49
10.12.2 Using two vacuum pumps........................................................................................................................ 51

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10.13 Router Setup................................................................................................................................................................51

10.14 Conveyor Belt Control..............................................................................................................................................51
10.14.1 Split Sheet Feed............................................................................................................................................ 52
10.14.2 Sheet Feed Correction................................................................................................................................ 52
10.15 Board Size.................................................................................................................................................................... 52

11. Tool Configuration and Adjustment................................................................................................................................53

11.1 Introduction..................................................................................................................................................................... 53
11.2 Adjust Active Tool.........................................................................................................................................................53
11.3 Lag Settings (for Rotating Tools)............................................................................................................................54
11.4 Tool Height Calibration...............................................................................................................................................56
11.5 Rotation Adjustment (for Rotating tools).............................................................................................................56
11.6 Center Offset Adjustment..........................................................................................................................................57
11.7 Manual adjustment of Center Offset and angle............................................................................................... 58
11.8 Tool Offset....................................................................................................................................................................... 59
11.9 Maintain Tool List (More...)....................................................................................................................................... 59

12. Tooling System.........................................................................................................................................................................61

12.1 Tool handling and care...............................................................................................................................................61
12.2 Tool Inserts with built-in motor............................................................................................................................... 61
12.3 Tool Heads available, overview...............................................................................................................................62
12.4 Tool Head mount / dismount................................................................................................................................... 63
12.5 FlexiHead......................................................................................................................................................................... 63
12.6 PowerHead......................................................................................................................................................................65
12.6.1 ø150 mm Crease Wheel............................................................................................................................... 66
12.6.2 Crease Adapter ø26 mm.............................................................................................................................. 66
12.6.3 Perforation Wheel ø60 mm..........................................................................................................................67
12.6.4 HD Knife Tool.................................................................................................................................................... 69
12.6.5 V-notch Knife..................................................................................................................................................... 69
12.7 FoamHead....................................................................................................................................................................... 72
12.8 MultiCut-HP.....................................................................................................................................................................75
12.8.1 Introduction.........................................................................................................................................................75
12.8.2 Safety Issues..................................................................................................................................................... 78
12.8.3 Precautions.........................................................................................................................................................79
12.8.4 Routing Advice..................................................................................................................................................83
12.8.5 Bits and Bit Change....................................................................................................................................... 86
12.8.6 Chuck Change and Clean............................................................................................................................88
12.8.7 Bit Slipping, Chuck Change........................................................................................................................ 91
12.8.8 Bit Length and Position................................................................................................................................ 91
12.8.9 Tool Adjustment................................................................................................................................................92
12.8.10 Table Top and Height Adjustment.......................................................................................................... 92
12.8.11 Miscellaneous..................................................................................................................................................94
12.8.12 Chiller, Error Conditions..............................................................................................................................95
12.9 Measuring Foot............................................................................................................................................................. 95

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12.10 Laser Pointer................................................................................................................................................................96

12.11 X-Pad.............................................................................................................................................................................. 96
12.11.1 X-Pad Calibration.......................................................................................................................................... 96
12.11.2 Tool Depth and X-Pad.................................................................................................................................97
12.11.3 Limitations........................................................................................................................................................ 97

13. Tool inserts.................................................................................................................................................................................99

13.1 Ball Point Pen................................................................................................................................................................ 99
13.2 Bevel Knife....................................................................................................................................................................100
13.3 Bevel Knife U20..........................................................................................................................................................101
13.4 Braille Tool.................................................................................................................................................................... 101
13.5 Crease Tool...................................................................................................................................................................106
13.6 Crease Tool, 60 mm................................................................................................................................................. 107
13.7 Drill tools........................................................................................................................................................................108
13.7.1 Flexi Drill Tool................................................................................................................................................. 108
13.7.2 Reboard Drill Tool..........................................................................................................................................109
13.7.3 Drill Bit dimensions.......................................................................................................................................109
13.7.4 Tool Adjustment............................................................................................................................................. 110
13.7.5 Drill Tool in ArtiosCAD.................................................................................................................................110
13.8 Foam Knife................................................................................................................................................................... 110
13.9 Ink Tool...........................................................................................................................................................................111
13.9.1 Liquid Ink Tool................................................................................................................................................ 111
13.9.2 Fibertip Tool.....................................................................................................................................................112
13.10 KissCut.........................................................................................................................................................................112
13.11 MicroCut......................................................................................................................................................................115
13.12 Psaligraphy Knife..................................................................................................................................................... 116
13.13 RBI 90-16 (Rigid Board Insert)...........................................................................................................................117
13.14 Reciprocating Knife.................................................................................................................................................118
13.15 Rigid Material Knife................................................................................................................................................ 120
13.16 RotaCut........................................................................................................................................................................121
13.17 Static Knife.................................................................................................................................................................123
13.18 VI45 Knife Tool..........................................................................................................................................................125

14. Maintenance............................................................................................................................................................................127
14.1 Daily maintenance......................................................................................................................................................127
14.2 Weekly maintenance................................................................................................................................................. 127
14.3 Maintenance, external equipment....................................................................................................................... 127

15. Fuse replacement.................................................................................................................................................................128

15.1 MPU fuses.................................................................................................................................................................... 128
15.2 X1 fuses......................................................................................................................................................................... 129
15.3 X2 fuses......................................................................................................................................................................... 130
15.4 Y/Z fuses....................................................................................................................................................................... 131
15.5 Tool Rotation/Reciprocating knife fuses........................................................................................................... 132
15.6 Chiller fuse.................................................................................................................................................................... 132

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15.7 Heater for Chiller Fuse.............................................................................................................................................134

16. Roll Feeder.............................................................................................................................................................................. 135

17. Collector Basket................................................................................................................................................................... 136

18. High-capacity Vacuum Cleaner......................................................................................................................................137

18.1 Introduction...................................................................................................................................................................137
18.2 Filter Shaking............................................................................................................................................................... 137
18.3 Remove Material Container................................................................................................................................... 138
18.4 Use Plastic Bag in Material Container.............................................................................................................. 138

19. High-capacity Vacuum Cleaner, Depureco............................................................................................................... 140

19.1 Introduction...................................................................................................................................................................140
19.2 Filter Shaking............................................................................................................................................................... 140
19.3 Remove Material Container................................................................................................................................... 141
19.4 Use Plastic Bag in Material Container.............................................................................................................. 141

20. Vacuum Cleaner 25............................................................................................................................................................. 143

21. Install Software......................................................................................................................................................................144

22. Frequently Asked Questions........................................................................................................................................... 145

22.1 Machine..........................................................................................................................................................................145
22.2 Tools................................................................................................................................................................................ 145
22.3 iPC....................................................................................................................................................................................146

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1

1. Preface
User Manual
for
Kongsberg XN
running i-cut Production Console 1.2

Note: We remind you that only the Esko staff, or persons having received appropriate training, are
allowed to handle, manipulate or do repairs on the system.

©Copyright 2016, Esko-Graphics Kongsberg AS, Norway

All Rights Reserved.

This copyright does not indicate that this work has been published.
This material, information and instructions for use contained herein are the property of Esko-Graphics
Kongsberg AS. There are no warranties granted or extended by this document. Furthermore, Esko-Graphics
Kongsberg AS does not warrant, guarantee or make any representations regarding the use, or the results
of the use of the system or the information contained herein. Esko-Graphics Kongsberg AS shall not be
liable for any direct, indirect, consequential or incidental damages arising out of the use or inability to use
the system or the information contained herein. The information contained herein is subject to change
without notice. Revisions may be issued from time to time to advise of such changes and/or additions.
No part of this system may be reproduced, stored in a data base or retrieval system, or
published, in any form or in any way, electronically, mechanically, by print, photoprint, microfilm
or any other means without prior written permission from Esko-Graphics Kongsberg AS.
This document supersedes all previous dated versions.
Correspondence regarding this publication should be forwarded to:
Global support
Esko-Graphics Kongsberg AS

Document no: D3564

Part no: 32597031

Esko-Graphics Kongsberg AS
www.esko.com
P.O.Box 1016, N-3601 Kongsberg, Norway
Tel: +47 32 28 99 00 Fax: +47 32 28 85 15 / 32 28 67 63

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2. Change Record
By Description
Date
dd-mm-yy
06-10-2014 jhbe First edition of this document
15-03-2015 jhbe Document is updated according to iPC ver 1.2
04-05-2015 jhbe X-Pad calibration, Static Knife tool removed
from list
11-06-2015 jhbe Reverse Operations in combination with Step
and Repeat, update
18-08-2015 jhbe Bit slipping and chuck replacement, chapter
added
13-10-2015 jhbe Braille tool chapter modified.
01-02-2016 jhbe Collector basket added
03-02-2016 jhbe Perforation Wheel ø 60 mm added

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3. Welcome

Welcome to the User Manual for Kongsberg XN running iPC.

This manual will provide a complete and detailed description of Cutting Table functions.
There is a separate user manual for i-cut Production Console (iPC). Thus, actual GUI functions will
be referenced in this manual, but the complete and comprehensive description is available in the
User Manual for i-cut Production Console.
This manual is aimed for operators of Kongsberg Cutting Tables and people preparing files for such
equipment.

Note: Some of the functions and equipments described in this manual are optional.

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4. Using this manual

4.1 Main Sections

The manual is divided into the following Main Sections:

Safety Regulations

• All safety related issues are discussed.

System Description

• This chapter provides basic knowledge about the machine.

Basic Operations
• This chapter provides basic knowledge about how to operate the machine.

Prepare for a Job

• A typical workflow is described, with detailed information about each step.

How to Procedures, Advanced

Optional functions for the advanced user:

• Cutting Thick Materials - advices.

• Hard Board Production - advices

• Multi Pass Milling - how to.

• MultiZone Production - how to.

Tool Configuration and Adjustment

• General information about the tooling and adjustment of tools.

Tooling System

• Tool descriptions.

Maintenance

• This chapter describes maintenance to be carried out by the customer.

Fuse Replacement

• Fuse location and specification.

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Appendices
• Roll Feeder - basic information.

• Vacuum Cleaner - basic information.

• FAQ - Frequently Asked Questions

4.2 Name Styles and Symbols

Name or style Description

Pop-up dialog This is the dialog that appears when you click the Right
mouse button.
Start button The italic style indicates this is a button on the Operator
panel.
OK The bold style indicates this is a button or function in the
GUI.
Maintenance Link to topic.

Menu selection: From Menu Bar, select Edit and then

Menu Bar->Edit-> Options Options.
This symbol indicates that the function depends upon
actual hardware.
If hardware is not available, this functions is hidden.
This symbol indicates that the function is license
dependant.

4.3 Pictures and Illustrations

Orientation
Pictures and illustrations related to the Cutting Table are viewed as illustated here:

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4.4 Local Languages

This manual is available in a wide range of local languages.

Screen pictures and illustrations remains in English language.

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5. Safety Regulations

5.1 Introduction
The XN 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.

• The table is used for Non-intended purposes.

In addition to the Safety Regulation described below, you will find safety warnings in the respective
topics.

5.2 Responsibilities

5.2.1 The Manufacturer

The Manufacturer is responsible for delivering the system according to Safety Regulation standards.

5.2.2 The 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 chapter.
• That the Local Regulations regarding installation and operation are fulfilled.

5.2.3 The Operators

The Operators are responsible for:

• Operating the system only when it is in a flawless state.

• Operating the system according to Operating Instructions.
• Ensuring that no Unauthorized Personnel come close to the system.

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5.3 Requirements to be met by operators

Personnel operating the system must:

• Be adequately trained.
• Have read and understood the instructions described in Safety Regulation as well as any other
safety warnings.

5.4 Definition of use

Intended use is described in the User Manual for i-cut Production Console.

In this manual, Intended use is described in the following chapters:

• Basic Operations

• Prepare for a Job

• How to Procedures, Advanced

Any other use is considered Non-intended use.

Examples of Non-intended use:

• Operation by operators not meeting the requirements as described above.

• Unauthorized modifications (bridging safety devices, removing covers etc.)
• Utilizing accessories other than those specified by Esko.

Non-intended use may cause:

• Health hazards and injuries.

• Damage to the system.
• Incorrect functionality.
• Damage to work materials.

Note: Esko is not liable for any damage resulting from such Non-intended use.

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5.5 Danger Zones

5.5.1 Danger Zones

The area around the moving parts is considered to be a Danger Zone.

The Danger Zone is identified by the means of a yellow / black floor marking.

5.5.2 Moving Parts, Laser Radiation and High Voltage

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5.5.3 Loose Clothing

While working with this machine, do not:
• Use ties
• Use loose necklaces
• Use scarfs

5.5.4 Noise Level

• Hearing Protection should be used by any personnel exposed to the noise

from the machine.

5.5.5 Ejection of Parts

Potential risk when running MultiCUT:
Personnel hit by breaking milling bit or small pieces of processed material.

• Eye Protection should be used by any

personnel working with MultiCUT.

5.6 Warning Sign Explanation

Knife Blades are extremely sharp.
This symbol is used in this documentation to indicate operations with Knife
Blades and Milling Bits.

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Hand Squeeze
Potential areas with a risk of being squeezed are marked with the Hand
Squeeze sign.
These areas are:

• Between X-axis end stopper and traverse wagon.

Do not Touch
Potential areas with a risk of being squeezed are marked with the Do Not
Touch sign.
These areas are:

• Between Y carriage and rack

• Between the table top and the moving traverse.
• Underneath the tool head.

Hearing Protection
The Hearing Protection symbol indicates areas where the use of hearing
protection is compulsory.

Eye Protection
The Eye Protection symbol indicates areas where the use of eye
protection is compulsory.

Moving Parts
Potential areas with a risk of being hit by Moving Parts are
marked with the Moving Parts sign.
These areas are:

• Both traverse ends.

• Y carriage.
• Tool head(s).

The Main Power Unit (MPU) contains Mains Voltage and

may be opened by Authorized Personnel only.

The MPU is marked with the High Voltage warning sign.

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Laser Radiation.
The tool head is equipped with a class II Laser Pointer.
Avoid laser light into your eyes.

5.7 Safety devices

5.7.1 Overview

Device no Description
1 Main Power Switch
2 Emergency Stop Button
3 Warning Lamp
4 Photo cell supervision, Dynaguard
5 Traverse Stop Switches, Dynaguard

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5.7.2 Emergency Stop Button

Switch positions:
OUT - Emergency Stop is switched OFF.
IN - Emergency Stop is switched ON; Servo Power to the machine is switched off.

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 Stop Distance of traverse, Y
carriage and Tool Head.

5.7.3 Warning Lamp on top of Y Carriage

Light is Description
Off Servo Power is off
On Servo Power is on, Safety System is enabled, table is in operation
Flashing Safety System is activated.
Reset Safety System to continue operation

5.7.4 DynaGuard Safety System

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The DynaGuard 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:

• One of the light beams is broken.

• The stop mechanism is activated, for instance when a person is standing too near the table.

Continue after DynaGuard is triggered

To continue operation, proceed as follows:

1. Ensure the table is free from obstructions and ready for operation.
2. Reset the Safety System by pressing the Pause pushbutton.
3. Observe that Servo Power is switched on,
4. Press Start to continue.

5.8 Protective equipment

For the operator(s), Esko recommends the following Protective Equipment:

Close-fitting clothes to avoid being caught by the beam or the tool head
which can cause injuries.

Gloves to protect against cuts from materials with sharp edges.

Eye protection should be used by any personnel working with milling.

Always use Hearing Protection when working with the machine for a
longer period of time.
The acoustic noise level will vary with the type of operation and tooling,
but a typical average level is 78.5 – 83.5 dBA and a maximum level of 98.5
dBA.

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5.9 Procedures in case of malfunctions

Trouble-shooting and repair shall be executed by Authorized Personnel only.
Contact a Esko Service Organization.

5.10 Residual Risk, XN

Despite all safety protection means incorporated in this machine, there are some Residual Safety
Risks to be aware of:

Beneath traverse end

1
The low part of the traverse ends is un-
protected.
Actions:
• Children are not supposed to be in the
machine area.
• Do not work or stay beneath the traverse
while the machine is working.

Y-carriage

2
The top of the Y-carriage is un-protected in all
four directions.
Actions:
• Do not bend down over the table or traverse
while the machine is working.

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Inside cable chain

3
There is a risk for squeezing between the cable
chain and the table base frame.
Actions:
• Stay out of this area while the machine is
working.

Rear side of traverse

4
The DynaGuard Safety System photo cell beam
c will stop the movement when hit.
When the Feeder Paws are mounted, the
distance between beam c and the mechanics is
reduced.
Actions:
• Stay out of this area while the machine is
working.

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6. System Description

6.1 Naming conventions

Machine

XN with front cover.

XN with Revolving Work Station and Conveyor belt

1 Table Top 7 Front cover including Operator Panel

2 Traverse 8 Main Power on/off switch
3 Y carriage 9 Traverse Safety Stop switches (DynaGuard)
4 Tools 10 Operator Station/Operator Panel
5 Main Power Unit (MPU), 11 Conveyor belt
Air Pressure Regulator
6 Emergency Stop button 12 Gallows for MultiCUT

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Axes

X - X-axis X1 - X1 end of traverse

Y - Y-axis X2 - X2 end of traverse
Z - Z-axis.

The arrows indicates positive moving direction.

6.2 Main Power Switch

Switch positions:
O - the Main Power to the machine is switched OFF.
I - the Main Power to the machine is switched ON.

6.3 Operators Panel

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Power On

Mains Power on/off indication.

Servo Power On

Servo Power on/off control.

Start

Press this button to Start Operation.

Pause / Safety System Reset

Press this button to Pause Operation and Reset Safety System.

Vacuum On/Off
Press this button to switch Vacuum On/Off.
Provides material hold down.

Set Panel Reference Point

Press this button to set Panel Reference Point.

If Fixed Reference Point is disabled, the current position of Laser
Pointer is set as the new Reference Point.

Move to Table Zero

Press this button, then the Start button, to move the tool head to
Selected Reference Point.
The Table Zero Mode is automatically selected at Power on.
The system remains in the Table Zero Mode until Table Zero movement
is completed.

Jog buttons

Press the Jog buttons to move the tool head in the desired direction.
The system must be in Pause mode, i.e. the Pause button must be lit,
for these buttons to be operative.

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Note: It is possible to configure the jog direction, see Option->System

setup.

Incremental Jog

Press this button to select Incremental jog mode.

Press the button a second time to disable Incremental jog mode.

Press the two arrows to move the tool head a large step.
Press the single arrow to move the tool head a small step.

The size of the incremental movement can be changed from Machine

Configuration->Setup.

Tool Down

Press the Tool Down button to manually operate the machine with a tool
in the down position.
Cancel by pressing Tool Down a second time.

Vacuum release mode

For details about this function, see separate chapter 'Vacuum control'.
If activated for more than 2 seconds, this button activates the Manual
Belt Clamp function.

6.4 Variable Blow Back

For conveyor belt::

The Blow Back function creates an air pillow
below the conveyor belt in order to reduce belt
friction.

For material handling:

The Blow Back function creates an air pillow
below the material in order to ease handling.

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Variable Blow Back - adjust the air flow to a
suitable level for the actual material.

Use this function to manually enable Blow Back.

6.5 Pressurized Air system

General
The High Pressure Air System supplies the valves and tooling with compressed air.

The compressed air input is connected to a

combined Pressure Regulator Valve/Water
Trap.
Wall Outlet - Wall Outlet
A - Air Tube
R - Pressure Regulator Valve
P - Pressure Gauge
W - Water Trap
T - Air Tube to Tools and Valves

For details regarding air supply requirements, see Site Preparation Manual.

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Air Pressure Regulator settings

The Air Pressure should be adjusted to

minimum 6 bar (6 kg/cm2, 6*105 Pa).
Recommended pressure level is 7 bar (7 kg/cm2,
7*105 Pa).

6.6 Application programs available

After installation of iPC, the following application programs are available

iPC
Control program for the Cutting Table.
For more information, see User Manual for i-cut Production Console.

SysLoad
Program for download of updates to CU–modules.

HWT800
Hardware test program, see separate HWT800 User Manual.

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7. Basic Operations
Keep away from Moving Parts during operation.
Do not lean on Racks, Guide Ways or Traverse during operation, as this may
cause personal injury.
Before starting any operation, make sure that:

• The Table is free from obstructions

• No unauthorized personnel come close to the table

7.1 Power On Sequence

Ensure the table is free from obstructions and ready for operation.

Follow these steps to power up the system and get ready to work:

1 Front End PC
Switch on the PC and the monitor.

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.

3 iPC
From Desktop, double-click the icon for iPC
Check that no error message indicates faulty conditions.

4 Safety System
Reset the Safety System by pressing the Pause pushbutton.

5 Servo Power
Press the Servo On pushbutton.
The Warning Lamp on top of the Y carriage should be on without flashing.

6 Table Zero Sequence

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Press Start pushbutton to complete the Table Zero Sequence.

The machine will move to the Selected Reference Point.

7 The table is now ready for operation.

7.2 Reset Safety System

Press Pause to Reset Safety System.

7.3 Power Off Sequence

Follow these steps to power down the system:

1 Servo Power
Press the Servo On pushbutton to switch Servo Off.

2 Table Power
Turn Table Power off using the Main Power Switch.
Note: After power off, wait minimum 5 sec. before the system is switched
on again.

3 Front End PC
To switch off the PC, use the Operating System shutdown procedure..

7.4 Continue after Safety Break

If the Safety System is activated, all movements on the table are stopped and the Warning Lamp
starts flashing.

To continue operation, proceed as follows:

1 Ensure the table is free from obstructions and ready for operation.

2 Reset the Safety System by pressing the Pause pushbutton.

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3 The Warning Lamp on top of the Y carriage should be on without flashing.

Observe that Servo Power is switched on,

4 Press Start to continue.

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8. Prepare for a Job

8.1 Introduction

Keep away from Moving Parts during operation.

Do not lean on Racks, Guide Ways or Traverse during operation, as this may
cause personal injury.
Before starting any operation, make sure that:

• The Table is free from obstructions

• No unauthorized personnel come close to the table

The Starting Point in this procedure is to Create a Job from a file already available in My Jobs List.
Detailed information about the complete iPC workflow is available in the User Manual for i-cut
Production Console.
Here, a step by step procedure is provided that can be used as a check list.

8.2 Create Job

In My Jobs List, double-click a file.

My Job Actions->Create Job.

A new Job is created based upon currently selected file in My Jobs List.

8.3 Layer Setup

Opened Job->Layers.

Ensure proper Layer Setup.

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8.4 Production Setup

Opened Job->Production Setup.

Verify correct Production Setup:

• Number of Copies
• Accuracy/Speed Prioritization
• Select Reference Point and Job Position
• Step and Repeat
• Registration
• Material Handling
• Tool Head Parking

8.5 Speed Setting

Opened Job->Production Setup->Quality.

Specify if this is a High Accuracy or a High Speed Job.

8.6 Flute/Grain Direction

Properties Bar->Flute/Grain Direction.

Verify that the Flute/Grain Direction corresponds to the material.

8.7 Vacuum Zone Selection

Machine Panel Toolbar->Vacuum Zones

From the Vacuum Zone setup – dialog, configure a suitable vacuum area for the job.
Select Vacuum Zones that corresponds to the outline of your material.

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Proper selection is important to achieve the best possible material hold down.

8.8 Job Execution

Before execution, check this:

1 Verify that Opened Job is ready for production.

2 Verify that the Table View display of the Job is reasonable.

3 Press Pause to reset Safety System.

4 Complete a Table Top Reference sequence to update Tool Height measurement.

5 Position the material on the Cutting Table.

6 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)

7 Press Start to execute the Job.

8.9 Milling Production

Before execution, check vacuum cleaner:

Ensure the vacuum cleaner container is prepared for the actual job.
Empty the container regularly.

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Note: Milling Jobs should be executed in High Quality mode.

8.10 Make a Pen Plot

Follow the procedure for how to prepare for and execute a job.

Ensure the Ballpoint Pen is clean and ready to use.

8.11 Work with X-Pad

Measuring modes

Machine Connection->Machine Configuration->Setup

Two modes are available:

Manual
Tool height is manually adjusted, using the tool height adjustment wizards available from the Tool
Configuration dialog.

Automatic
The tool height is automatically measured, using X-Pad as described in next chapter.

Automatic tool height measurement using X-Pad

Measure all tools, started from GUI, procedure

Menu Bar->Machine->Adjust Tool Height

Machine Panel Toolbar->Tool Height

• A wizard dialog appears.

• Follow the instructions in the wizard to complete calibration.

Measure all tools, started from Operators panel, procedure

1 • Press the Pause button for more than 2 sec.

2 • While the Pause button is down, press the Tool override down button

• Release both buttons.

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• The measuring sequence is started.

3 • Place the measuring pad with the Laser spot in center or jog the machine
until the Laser spot is in the middle of the measuring pad.

• Press Start to initiate measuring.

Indication that the measuring sequence is active

A measuring sequence is indicated by:
• Continuous light in the Tool Override Down button.
• Continuous light in the Laser Pointer.
• Start button light is flashing.
• Pause button light is off.

Measure one tool, procedure

Machine Connection->Tool Configuration

• From the dialog, select the tool to be measured.

• Select Adjust Active Tool.
• Select Tool Height Calibration.
• A wizard dialog appears:

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• Press the Measure Tool button.

• A wizard dialog appears.

• Follow the instructions in the wizard to complete calibration.
• Height Settings
Current setting: The automatically measured height value.

• Automatic Measurement Adjustment

New offset setting:
Use this value to modify the height measured by the Measuring Pad. Negative value means
down into the material.
Current offset setting:
The initial offset value (when the dialog was opened) is displayed.

How to start a measuring sequence in the middle of a job

Two methods are available:
1. Measure after Stop at Tool Select (Stop before use). The execution will stop for each tool change
and a tool height measuring sequence can be carried out.
2. You press Pause.
In both cases the tool height measuring sequence should be started from the Operators Panel
as described above.

How to cancel measuring or calibration

All Measuring Pad operations are cancelled by:
• Press Close in the active dialog.

• Press Pause on Operators Panel

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9. How To Procedures, Advanced

9.1 Cutting Thick Materials

When preparing materials with thickness between 45 – 50 mm (1¾ - 2 in.), the following rules apply:

• No Camera operations are available.

• Disable Measure Material Thickness.

• Disable the Depth Referenced from Top function.

• This function is for Knife Tools only.

Cutting Depth when Depth Referenced from Top is disabled

Note: This function is useful for all materials with an un-even surface.

9.2 Hard Board Production

To prepare hard board materials, the procedure

is as follows:

1. Mill through the top layer using MultiCUT.

2. Cut through the mid-section using the HF
VibraCut Knife.
3. Mill through the bottom layer using
MultiCUT.

1. Ensure that the Router Bit is sharp and proper for the job.
2. Ensure that the Knife Blade is sharp and proper for the job.

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9.3 Multi Pass Milling

Opened Job->Layers->Edit Layer

Menu Bar->Layer->Edit Layer

1. pass 2. pass 3. pass - mill through and clean

the path

Multi Pass Milling is beneficial if you want to mill through a material where the thickness is bigger
than the router bit diameter.

9.4 Jobs including Reverse Operation

Step 1 - the sheet is aligned towards the Right Step 2 - the sheet is aligned towards the Left
Ruler. Ruler.

Reverse Operations are completed. The rest of the job is completed.

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A typical use of Reverse Operation is when you want to add a crease line on the front side of a
material that you normally prepare from the rear side.
Reverse Operation is available by modifications of the actual Layer.
This function requires that the table is equipped with left and right rulers.

Note: Reverse Operation is not available on machines with conveyor belt.

Reverse Operation in combination with Step and Repeat

For each copy defined by Step and Repeat, you have to move the sheet; first against the Right
Ruler, then against the Left Ruler:

9.5 Work with different Reference Point Settings

Select the Reference Point to use from:

Opened Job->Production Setup->Position->Reference Point

For more information, go here.

9.6 MultiZone Production

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Introduction
In User Manual for i-cut Production Console, general information about MultiZone Production
is available.
In this chapter, XN - specific issues are described.

Vacuum Zones
Vacuum Section Configuration on page 49

MultiZones

The illustration shows the most actual zones available for MultiZone Production

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10. System Setup

10.1 Introduction
This chapter will explain functions and parameters that are important for the XN system to run
properly.
It is a supplement to the information available from the User Manual for i-cut Production Console.
Examine each step carefully to ensure proper settings:

One time adjustments completed at the factory

The functions are included here as a reference.
They are not used during normal operation.
If necessary, they should be repeated, as indicated in the function description.

1 Adjust X1 to X2 Angle

2 Register Table Size

4 Set Ruler Position

5 Set Main Reference Point

6 Map Table Top Surface

8 Vacuum Setup

9 Router Setup

Adjustments to customize the table

1 Select Reference Point

2 Set Table Speed

3 Set Table Acceleration

4 Jog Settings

5 Set Table Top Reference

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6 Conveyor Belt Control

7 Board Size

10.2 Adjust X1 to X2 Angle

Machine Connection->Machine Configuration->Installation_>Adjust X1 to X2 Angle

Use this wizard to obtain correct angle between X axis and Y axis.
Typical use is after maintenance or repair.

Procedure:
1. Execute the Adjust X1 to X2 Angle function.
2. Follow the instructions exactly as given by
the wizard.

Note: Select a set of drilled vacuum holes (1 and

2) in the table top as reference.

10.3 Register Table Size

Machine Connection->Machine Configuration->Installation_>Register Table Size

This wizard moves the Tool Head from edge to edge of the Cutting Table in order to measure the
table size.
Typical use is after maintenance or repair.
Procedure:

1. Execute the Register Table Size function.

2. Follow the instruction given by the wizard.

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10.4 Set Ruler Position

Machine Connection->Machine Configuration->Installation_>Set Ruler Position
Follow instructions from the wizard.

If your table is equipped with Rulers, please complete the wizard for left and right ruler.
For the table to operate properly an exact registration of the Ruler Positions is necessary.
This is a one time job, but it can be necessary to repeat the procedure if mechanical maintenance
has been carried out on the table or traverse.
Correct registration of the Right Ruler is required when Reverse Operations are carried out.

10.5 Set Main Reference Point

Machine Connection->Machine Configuration->Installation_>Set Main Reference
Position
Follow instructions from the wizard.

Use this wizard to establish the Main Reference Point (R).

Typical use is after maintenance or repair, if the Main Reference Point has been accidentially moved.

The Main Reference Point is a fixed position on the Cutting Table marked as a cross of drilled holes.
For more information, go here.

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10.6 Map Table Top Surface

Machine Connection->Machine Configuration->Installation_>Map Table Top Surface

To assure correct Cutting Depth, the surface of the Table Top is measured in order to create a map.
It is recommended to execute this function if the Cutting Mat is worn out and after the Cutting Mat
has been replaced.

Procedure:

1. If the table is equipped with a Conveyor Belt, move the belt junction away from the table surface.
2. Execute the Map Table Top function.
3. Follow the instructions given by the wizard.

10.7 Reference Points and Coordinate System

Reference Points settings is maintained from:

Menu Bar->Edit->Options...->Reference Points

All X and Y coordinates in the Input File have the selected Reference Point as origin.
Two modes of operation are available:

• Using Main Reference Point

• Using User Defined Reference Point

The Main Reference Point position

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The Main Reference Point is a fixed position on the Cutting Table marked as a cross of drilled holes.
The User Defined Reference Points are all specified relative to the Main Reference Point.
Thus, moving the Main Reference Point will move these reference points as well.
The Main Reference Point has to be correctly positioned in order to obtain:
• A full Work Area.
• Correct Sheet Feed operation.
• Correct handling of Long Jobs
Using the Main Reference Point during program execution ensures correct operation.

User Defined Reference Points

You can specify User Defined Reference Points.

User Defined Reference Points are used if you want your job positioned in a fixed position on the
table (Rx), but not in the Main Reference Point (R).

A special version of User Defined Reference Point is the Panel Reference Point.

1 Position the Laser Pointer in the position where you want your Panel Reference
Point.

2 Press the Set Reference Point button on Operators Panel.

The Panel Reference Point is set to current Laser Pointer Position

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Rulers and Reference Points

The Ruler System ensures an easy and correct

positioning of the material on the table.
The Main Reference Point shall be defined dr =
10 mm/0.39 in. inside the ruler.

When you use the Right Ruler, the Reference

Point will automatically be moved to an identical
distance from the Right Ruler, as it is defined
from the Left Ruler.
The Right Ruler is normally used for Reverse
Score operations. At the same time the direction
of the X axis is reversed.

10.8 Table Speed

Menu Bar->Advanced->Configure Tools...->Velocity X/Y
This is the default value for each Tool when Layers are created.
Opened Job->Edit Layer->Speed X/Y
Modify Speed for this particular Job.
Opened Job->Production Setup->Quality
Here you specify if this is a High Quality Job or High Speed Job.

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10.9 Table Acceleration

Menu Bar->Advanced->Configure Tools...->Acceleration
This is the default value for each tool when Layers are created.
Note: Acceleration can be reduced to a % value of the maximum acceleration available.
Opened Job->Layers->Edit Layer->Acceleration
Modify acceleration for this particular Job.

10.10 Jog Settings

Continuous Jog speed
The Continuous Jog Speed can be reduced to a % value of the maximum jog speed:
Machine Connection->Machine Configuration->Setup_>Jog Speed
Specify low and high Jog Speed

Incremental Jog Step Size

The size of the Incremental Jog movements can be customized.
Machine Connection->Machine Configuration->Setup_>Incremental Jog
Specify Step Size to be used.

Jog Directions
Machine Connection->Machine Configuration->Setup_>Jog Panel Direction
Use this function to align the Jog Directions with the orientation of the Operator
Station.

10.11 Set Table Top Reference

Menu Bar->Machine->Set Table Top Reference
Follow instructions from the wizard.
Machine Connection->Machine Configuration->Installation_>Table Top Reference
Follow instructions from the wizard.

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Machine Panel Toolbar->Table Top Reference

Use this function to complete a Tool Height Reference calibration.

The Tool Height is measured in current position and the reference to the table top surface is updated.
This calibration is the basis for Tool Height calculation.

The Table Top Reference function should be carried out:

• After mechanical adjustments of traverse or tool head.

• When cutting through material is not working properly.
• After any change of cutting / milling underlay, for instance, after adding or removing the milling
underlay.

Procedure:

1. Remove all materials from the table surface.

2. Measure on top of the cutting underlay or conveyor belt.
3. If the table is equipped with a conveyor belt, avoid measuring directly on the belt junction.
4. Execute the Table Top Reference function.
5. In the wizard, press OK to start measurement.

10.12 Vacuum Setup

10.12.1 Vacuum Section Configuration

Machine Connection->Machine Configuration->HW Configuration->Vacuum Setup

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This is a 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.

Machine Zone Configuration Vacuum Configuration

XN20 #14

XN22 #14

XN24 #12

XN40 #14

XN44 #12

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Machine Zone Configuration Vacuum Configuration
XN46 #5

XN48 #13

10.12.2 Using two vacuum pumps

Machine Connection->Machine Configuration->HW Configuration->2 Vacuum
Pumps

Enable this parameter if your machine is equipped with two vacuum pumps (option).
Note: When running two vacuum pumps, the start of the second pump is slightly delayed.

10.13 Router Setup

Machine Connection->Machine Configuration->HW Configuration->Router Setup

From the Router Setup dialog, maintain the following parameters:

Specify Router
If a Router is mounded, spedify Router Type.
If no Router is mounted, select None

COM-port
The physical COM-port used for communication with the Router Control Unit is specified.
Note: The Router Control Unit needs to be connected to a genuine COM port. If connected to a
USB-to-COM adapter, the communication will fail.

These functions are used only after a hardware modification.

10.14 Conveyor Belt Control

Machine Connection->Machine Configuration->HW Configuration->Conveyor

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Specify if the machine is equipped with Conveyor Belt.

10.14.1 Split Sheet Feed

Sheet in Load Position Sheet Load, step 1 Sheet Load, step 2

In some occasions, the sheet unloaded from the cutting table can trigger the photo cell safety system.
To avoid this, the sheet feed movement is divided into two steps.

10.14.2 Sheet Feed Correction

If the Conveyor Belt feed length needs adjustment, use this function to adjust the movement of the
Conveyor Belt to be shorter or longer.

10.15 Board Size

Not implemented yet

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11. Tool Configuration and Adjustment

11.1 Introduction

Machine Connection->Tool Configuration

The Tool Configuration dialog is used for all tool settings and adjustments.

11.2 Adjust Active Tool

From the Adjust Selected Tool – dialog, all Tool Adjustment Wizards are executed.
The following procedures are general descriptions of how to adjust the tools.

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See the description of each Tool Type for more specific information:
We recommend using a sheet of Folding Carton material, 5-6 mm / 0.2 inch, when executing the
adjustments.

Note: All tools need to be adjusted in the position they will be used.

Before any adjustment, complete a Table Top Reference function:

Menu Bar->Machine->Set Table Top Reference

Machine Panel Toolbar->Table Top Reference

11.3 Lag Settings (for Rotating Tools)

1. In the Configure Tool dialog, select the tool to be adjusted.

2. Press the Adjust Active Tool button to enter the Wizard Selection
dialog.
3. Select Lag Settings
4. Follow the instructions given to enter correct values.
5. Repeat the procedure for all rotating tools.

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Lag Setting

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, see below.

Width – knife bottom width

Enter the measured knife bottom width.

Lag Test

Run this wizard to obtain correct Knife Lag

value.
Follow the instructions in the dialog.
Add the measured value to the displayed value.

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Circle Lag

Circle quality is determined by a parameter

called Circle Lag. The parameter value will vary
depending upon the actual material.
Therefore, the adjustment is located in the Job
Setup dialog.

11.4 Tool Height Calibration

1. Select the Tool to be adjusted

2. Press the Adjust Active Tool button to enter the wizard selection dialog.
3. Select Tool Height Calibration
4. Follow the instructions given by the wizard, step by step.
5. Repeat the procedure for all tools.

11.5 Rotation Adjustment (for Rotating tools)

Optimal Angular Offset may vary with different material strength and thickness.
The adjustment can be done using the adjustment wizards, or by a manual adjustment procedure:

Adjustment using Wizard

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1. Select the Tool to be adjusted.
2. Press the Adjust Active Tool button to enter the wizard selection dialog.
3. Select Rotation adjustment.
4. Follow the instructions given by the wizard, step by step.
5. Repeat the procedure for all Tools mounted.

Manual Adjustment

1. Place an appropriate test material on the table, and switch Vacuum On.
2. From Tool Configuration dialog, select one Tool.
3. Press Adjust Active Tool to enter the Wizard Selection Dialog.
4. Select Manual Adjustment of Center Offset and Angle.
5. Enter value for the Angular Offset and select Activate.
6. Note that the Tool will rotate as the new value is activated.
7. Press Tool Override Down, and Jog approximate 10 cm to make a test cut.
8. Press Tool Override Down once more to lift the Tool again.
9. Press Tool Override Down once more to lower the Tool again.
10.Note how the knife enters into the material.
11.Press Tool Override Down once more to lift the Tool again.
12.If knife enters exact into the cut, the angle is correct; select Finish to exit.
13.If seen in the cutting direction, the knife enters to the left of the cut, the Angular Offset Value
should be decreased. Repeat from point 5.
14.If seen in the cutting direction, the knife enters to the right of the cut, the Angular Offset Value
should be increased. Repeat from point 5.

11.6 Center Offset Adjustment

The adjustment can be done using the Adjustment Wizards, or by a Manual Adjustment procedure:

Adjustment using Wizards

1. Put an appropriate test material, that means a thin paper on the table (any significant material
thickness will create a misleading offset in this wizard).
2. Switch vacuum on.

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3. Select the Tool to be adjusted.

4. Press the Adjust Active tool button to enter the wizard selection dialog.
5. Select Center Offset Adjustment.
6. Follow the instructions given by the wizard, step by step.
7. Repeat the procedure for all Tools mounted.

Manual Adjustment

1. Place an appropriate test material on the table, and switch Vacuum On.
2. From Tool Configuration dialog, select one Tool.
3. Press Adjust Active Tool to enter the Wizard Selection Dialog.
4. Select Manual Adjustment of Center Offset and Angle.
5. Enter value for the Center Offset and select Activate.
6. Note that the Tool will move as the new value is activated.
7. Press Tool Override Down, and Jog approximate 10 cm to make a test cut.
8. Press Tool Override Down once more to lift the Tool.
9. Press the Jog button for the return direction shortly, just to turn the Tool.
10.Press Tool Override Down once more to lower the Tool, and Jog the same distance back.
11.Press Tool Override Down once more to lift the Tool.
12.The two cuts should follow exactly the same path.
13.If exact, the Center Offset is correct, select Finish to exit.
14.If not, modify the Center Offset Value and repeat from point 6.

11.7 Manual adjustment of Center Offset and angle

Sometimes, it might be necessary to fine-tune

the adjustments obtained using the wizards.
Use this dialog to modify the adjustment values
for angle and center offset.

1. Select the tool to be adjusted.

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2. Press the Manual adjustment of…. button to enter the adjustment dialog.
3. Key in or use the up/down arrows to specify the wanted offset.
4. Press Activate to enter the value.
5. Test the new settings.

Note:
All 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.

11.8 Tool Offset

The Laser Pointer is the reference:

1. Place an appropriate test material on the table, and switch Vacuum On.
2. Select the Tool to be adjusted.
3. Press Adjust Active Tool to enter the Wizard Selection Dialog.
4. Select Offset Adjustment.
5. A cross is made by the Tool to be adjusted.
6. The Laser Pointer is positioned in the center of the cross.
7. If necessary, jog the Laser Spot into the center of the cross.
8. Follow the instructions given by the wizard, step by step.

11.9 Maintain Tool List (More...)

The More.. dialog contains selections to Ignore, Delete or Add to the Tool List.
The Tool List contains Tools that you can select for the available Tool Positions.

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Ignore Automatic Tool Identification

Ignore Automatic Tool Identification may be used when the Automatic Tool Detection fails, and
manual tool selection is necessary.
If Ignore Automatic Tool Identification is checked, Tool Setup remains unchanged after:
• Table Zero Position sequence

• Identify Tools function

Delete Tool
Use Delete Tool when a Tool is no longer in use.
The deleted Tool will no longer be available in the Tool List in the Edit Layer dialog.

Add Tool
Use Add Tool to
• Add new Tools

• Add tools that fails during Automatic Tool Detection

The Tool is added to the Tool List.

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12. Tooling System

Knife Blades are extremely sharp.

Take care when handling Knife Tools.

Laser Radiation.
Do not stare into beam!
The tool head is equipped with a class II laser pointer. Emitted laser power <
1 mW.

12.1 Tool handling and care

All tools are precision instruments and should be treated as such to ensure proper operation.

Take special care when:

• Tools are inserted or removed from
their stations. No excessive force
should be applied.

• Tools should not come in

contact with hard surfaces while
removed from their stations either
temporarily or for storage.

• The Tools and their stations should

be kept clean with a soft brush.

12.2 Tool Inserts with built-in motor

Some of the tool inserts has a built-in motor, such as the reciprocating knife tools, RotaCut and the
FlexiDrillTool.
Only one motor drive outlet is available, thus, the number of such tools that can be used at the same
time is limited to one.
It is recommended to remove any such unused tools from the tool holder.

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Motor cable and connector

When disconnecting the motor cable, use the

plug.

12.3 Tool Heads available, overview

FlexiHead
FlexiHead is a Multi-purpose Tool Head prepared for the following tools:

Bevel Knife KissCut Knife Pen

Crease Tool Knife Tool Psaligraphy Knife
Drill Tool MicroCut Reciprocating Knife
Foam Knife RotaCut Knife

PowerHead
PowerHead is a special purpose Tool Head, which can be equipped as follows:
• Two general tool positions prepared for the standard FlexiHead tools.

• PowerHead Creasing Tool for heavy duty creasing with high pressure and suitable wheel
geometry.

• V-notch Knife. Prepare a V-cut in triple-wall materials.

• HD Knife Tool

FoamHead
FoamHead is a single position tool head for cutting foam materials with thickness up till 86 mm (3
3/8").

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MultiCut-HP
MultiCUT-HP is a special purpose tool head, which can be equipped as follows:
• Two general tool positions prepared for the standard FlexiHead tools.

• Milling tool equipped with a high speed milling spindle.

12.4 Tool Head mount / dismount

>>

>> Be careful not to apply too much force when

fixing the signal cables.

12.5 FlexiHead

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Tool Head Description

1. Tool positions 1, 2, 3 with locking knobs

2. Outlet for Reciprocating Knife motor
3. Laser pointer
4. Measuring foot / material hold down foot. Has 3 functions:
a. Measure the thickness of the material on the table
b. Mapping Table Top Surface.
c. Keep material down during knife operations

Replace a Tool Insert

Observe the alignment pins Press the locking knob down

Tool Adjustments, FlexiHead

Tool Height
Correct tool height relative to table top

Lag Setting

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Tool Rotation
Adjust tool angle tangential to moving direction

Center Offset
Adjust tool sideways until centered

Tool Offset
Adjust offset to Laser Pointer.

12.6 PowerHead

Tool Head Description

1. Tool position 1 (FlexiHead tool insert)

2. Tool position 2 (FlexiHead tool insert)
3. Tool position 3
4. Laser Pointer
5. Measuring foot / material hold down foot
6. Electrical connection, reciprocating motor

Tool Adjustments, PowerHead

Tool Height
Correct tool height relative to table top

Lag Setting
The lag value depends upon the blade adapter. Nominal value is 0 mm.

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Tool Rotation
Adjust tool angle tangential to moving direction

Center Offset
Adjust tool sideways until centered

Tool Offset
Adjust offset to Laser Pointer.

For more information about how to run the adjustment wizards, see Tool Configuration.

12.6.1 ø150 mm Crease Wheel

This Crease Wheel has the equivalent of 50kg [110lb.] 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.

How to mount / dismount the Crease Wheel

Insert / remove the latch pin. Insert / remove the Cotter Pin.

12.6.2 Crease Adapter ø26 mm

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The Crease Adapter allows 26 mm (1 in.) crease
wheels to be used in the Heavy Duty crease tool
position. The tool is adjusted and operates as an
ordinary crease tool.

12.6.3 Perforation Wheel ø60 mm

Use Perforation Wheel to prepare perforation lines at high speed.

Suitable for corrugated board up to C flute (4 mm/0.16 in.).

Perforation Wheel assembly

Parts in assembly

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Ensure the path is clean.

Fix cover properly.

Push / pull the perforation wheel in / out from the

adapter.

Tool Adjustment
For this tool, complete the following adjustments:
Adjustment Description
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.

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For more information about how to run the Adjustment Wizards, see the Tool Configuration chapter

12.6.4 HD Knife Tool

The HD Knife Tool is inserted in the HD crease

tool position. The tool is adjusted and operates
as an ordinary knife tool.

Knife Blade correctly positioned inside the The HD Knife Tool is ready with the Knife Blade
adapter. mounted.

12.6.5 V-notch Knife

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V-notch Knife mounted on a Heavy-Duty Unit.

How to insert / remove V-notch Knife

Turn the V-notch Knife (A) correctly to fit the Both latch pins are used for the V-notch Knife.
alignment pin (B).

How to replace a Knife Blade

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 blade clamping.
clamping. 2. Carefully remove the blade (1).
3. Insert a new Knife Blade and make sure that
it is aligned with the alignment pins in the tool
head.
4. Mount the new tool.
5. Select Option->Tool Configuration ->Adjust
Active Tool->Tool Height Calibration
wizard, to assure correct height of the new
knife.

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.

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Single Cut
Set from Edit Layer.

Double Cut. This is the default mode if neither

Single Cut nor Triple-Cut are enabled.
Set from Edit Layer.

Triple-Cut. Set from Edit Layer.

Tool adjustment
• For the V-notch Knife, we recommend the manual procedures for tool rotation and centre offset
adjustment.

• When adjusting tool rotation and centre offset, use a thin Folding Carton material.

• Remember that you should look at the bottom side of the material for correct alignment.
• The adjustment depends upon the actual material due to weight, structure and thickness. For
optimal result, a fine tuning of the adjustments in the actual material should be carried out.

Tool Height
Correct tool height relative to table top

Lag Setting
Nominal value is 0-7 mm.

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Tool Rotation
Adjust tool angle tangential to moving direction

Center Offset
Adjust tool sideways until centered

Tool Offset
Adjust offset to laser pointer

For more information about how to run the adjustment wizards, see Tool Configuration.

V-notch Knife settings are maintained from:

Opened Job->Layers->Edit Layer

Menu Bar->Layer->Edit Layer

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 dialog.
3. Normally the cut should extend down to just above the bottom liner closest.

How to set the width of the V-notch cut

From the dialog, modify the default width.

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.

12.7 FoamHead

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1. Height sensor
2. Knife adapter
3. Material hold down wheels. Operator protection.
4. Laser pointer

Tool Adjustments, FoamHead

Tool Height
Correct tool height relative to table top

Lag Setting
Default lag value for the long foam knife is 4.5mm/0,18"

Tool Rotation
Adjust tool angle tangential to moving direction

Center Offset
Adjust tool sideways until centered

Tool Offset
Adjust offset to Laser Pointer.

For more information about how to run the adjustment wizards, see Tool Configuration.

Partial through cut

Partial through cut is specified as an absolute value or a percentage value in the Job Setup dialogue.
Please note that the value is specified from the top of the material and down.

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Cutting quality
To obtain best quality when cutting details, as small circles, we recommend:
• Reduce the cutting speed (from Job Setup)
• Cut in two or three passes, each pass going a step deeper (Multi pass).

How to replace a Knife Blade

Loosen the fixing screw, replace the Knife Blade
and fix it again.

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.

Disable Material Thickness Measurement

Opened Job->Production Setup->Material Handling

For the Foam Knife Tool, the Disable Material Thickness Measurement function is available.
Use this function if

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• Your foam material is too soft for the measuring system.
• The surface of your material is un-even.

When the Disable Material Thickness Measurement function is enabled, the following rules
applies:
• Depth is referenced from bottom (top of cutting underlay).
• During Tool Up movements, the knife is lifted to its top position.

12.8 MultiCut-HP

Router Bits are extremely sharp!

12.8.1 Introduction

MultiCUT-HP

1. Tool position 1 (FlexiHead tool insert)

2. Tool position 2 (FlexiHead tool insert)
3. Laser pointer
4. Tool position 3
5. Measuring foot / material hold down foot
6. Electrical connection, router spindle motor

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7. Electrical connection, reciprocating motor

8. Suction hose
9. Cooling water connectors

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. Warning lamp for spindle running.
4. Chuck open/close. The shown position is closed. Note: Ensure there is a router bit inserted when
the Chuck is closed.
5. Air clean button to help remove contamination.
6. Locking screw for the suction house. This screw is used when you want to lock the suction house
in a certain height.

1. Router bit. Shaft diameter is 6 mm (CL) and 6/8 mm (HP).

2. Chuck. MultiCUT-HP is equipped with one 6 mm Chuck on delivery.
3. Spindle

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Water tube connections
Connect water tubes: Push the tube connectors
into the receptors. Sequence is not important.

Release water tubes: Pull down the release

locker on each connector.

The suction tube is fixed to the suction house.

When MultiCUT-HP is not in use, the suction

tube and the water tubes are fixed to the
traverse as shown here.

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Chiller / MultiCUT-HP 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.

Suction house, adjustable height

On MultiCUT-HP, you can lock the suction house in any height; still it is allowed to move upwards.
This function is useful in order to
• Adapt to different material thicknesses.
• Allow false air input in order to reduce suction force.

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.

12.8.2 Safety Issues

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.

Eye protection
Use eye protection when working with MultiCUT/MultiCUT-HP.

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Hearing protectors
The noise generated by MultiCUT/MultiCUT-HP highly depends upon the material processed, and
running parameters. Use hearing protectors when necessary.

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.

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.

High temperatures
Be aware that the MultiCUT may become hot during operation.

Clean surface
Keep the table and material surface clean, free from obstacles.

12.8.3 Precautions

Spindle motor power consumption supervision

Too high spindle power consumption indicates
critical conditions for the motor and immediate
actions should be taken:
• Use correct and sharp milling bit.
• Use correct RPM for the actual bit and
material.
• Reduce the X/Y speed.
If the motor is running above a critical limit, the
execution will stop and a message is displayed.

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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 (MultiCUT) 60.000
(MultiCUT-HP).

Keep distance d small

For best performance and minimum wear, do not
let the bit stick out more than necessary. Use
bits with short cutting lengths for thin materials.

Air valve operation

Never operate the air valve while the spindle is
running. This will destroy the spindle.

Air pressure
Never run IBAG spindle with air pressure disconnected
This may destroy the spindle.
Keep this in mind also for test purposes.

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Use clean air
The spindle is sensitive for the pressurized
air quality. Regularly check the air pressure
reduction valve according to the maintenance
section.

Maintain bit clamping

Un-proper clamping may cause the bit to slip in
the Chuck and damage to the table top.
1. Keep the bit shafts clean. Avoid greasy
fingers. Clean the bit shafts with acetone if
necessary, but use only dry cotton tips on the
Chuck.
2. Maintain air supply pressure of 7 bar.
3. Follow procedures for Chuck change and
clean strictly.

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 (MultiCUT).
MultiCUT-HP spindle is water cooled, thus, the
ambient temperature is not that critical for the
spindle itself.

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Long term storage

More than 4 weeks storage of a spindle or a
MultiCUT/MultiCUT-HP requires:
1. Turn the spindle by hand about 20 turn every
4 weeks.
2. Spindle must be stored horizontally.

Consider having a replacement spindle

If the MultiCUT/MultiCUT-HP is used in regular
production, it is recommended to have a
replacement spindle.
The service interval will depend on the type of
operation, and is difficult to predict.
Indication of worn bearings may be increasing
noise, increasing vibrations or decreasing
surface finish.
Note: When replacing a spindle, torque the
motor clamp to 5 Nm, 44 lbf-in using a torque
wrench. This is a low torque for that screw
size. Also check by hand that the spindle rotates
smooth without any resistance.

Empty vacuum cleaner in time

Do not leave the machine running if the vacuum
cleaner can go full. This might cause damage.

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12.8.4 Routing Advice

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.

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Bits with small cutting diameters (3-4 mm;

0.12-0.16 in) are more balanced than bits with
larger cutting diameters, allowed to 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 (MultiCUT) 40.000.
Max RPM (MultiCUT-HP) 60.000.

Edges are brittle.

Never let bits touch each other, or other hard
surface. Always store in proper container.

Acrylic or Multi Purpose bits

Acrylic bits (A) are polished, extra sharp for
Acrylic, 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.

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Feed rates
One-flute bits do have a good chip flow, and
allow for large feed rates.
0.1-0.2 mm/tooth (0.004-0.008 in/tooth) can be a
starting point for optimization in most materials:
This gives a feed rate of of 4-8 m/min (2.6-5.2
ips) at 40.000 RPM, and 6-12 m/min (3.9-7.9 ips)
at 60.000 RPM.
Light materials like PVC foam can be run
much faster. The surface finish or the power
consumption will normally determine the final
feed rate for an application.
A large drop in RPM, or a high %Watt value in
the display, indicate too high feed rate.
Large diameter bits require more power than
small diameter bits.
Worn bits increase the power

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.

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:
• Use bits with smaller cutting diameter
• Cover unused table area
• Use wash-out functions instead of cutting loose small waste parts.

Milling direction
The milling direction is important i order to
obtain a good result. Correct directions 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.

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KissCut and MicroCut knife tools on MultiCUT/MultiCUT-HP

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.

12.8.5 Bits and Bit Change

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

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Only the round part of the shaft should be inside
the Chuck.
See the ‘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.

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.

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12.8.6 Chuck Change and Clean

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 increase 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 for MultiCUT-HP) key

to hold the spindle rotor.
Note: Do not turn the rotor when in CHUCK
OPEN position. This might damage the spindle.

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Enter the Chuck tool with a dummy bit to the
Chuck.

Hold the rotor with the 13 mm (17 mm for

MultiCUT-HP) key and unscrew the Chuck with
the Chuck tool.
Note: If you can not move the Chuck with
the Chuck tool, another 10 mm (12 mm for
MultiCUT-HP) 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.

Push the air clean button to help remove

contamination.

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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 lbf-in).
Hold the rotor with the 13 mm/17 mm key.

Close the Chuck on a dummy bit.

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Chuck maintenance kits are available on the
Esko web shop, www.esko.com.

12.8.7 Bit Slipping, Chuck Change

Even though the chuck is expected to have a long lifetime, replace it immediately if you experience
any problems as:

• Bit slipping.
• Bit vibrations.

When replacing the chuck, follow instructions in Chuck Change and Clean.

New chucks are available from Esko store.

12.8.8 Bit Length and Position

Keep distance d small. For best performance
and minimum wear, do not let the bit stick out
more than necessary. Use bits with short cutting
lengths for thin materials.

For proper clamping, keep distance e 20 mm,

0.8 inch as a minimum.

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To achieve material through-cut, the distance d

must be at least 18 mm, 0.7 inch.

Balanced bits Bits with balanced surface should

have a clamping length f of min. 20 mm/0.8
inches. Maximum balancing length g is 12 mm /
0.5 inches.

12.8.9 Tool Adjustment

For FlexiHead tool positions, complete relevant adjustments as described for FlexiHead.
For the router position, complete the following adjustments:
Tool Height
Correct tool height relative to table top.
The tool tip should touch the material surface.
Tool Offset
Adjust offset to Laser Pointer.

For more information about how to run the adjustment wizards, see Tool Configuration.

Notes regarding Tool Height adjustment:

When properly adjusted, the router bit should barely touch the top surface of the material.

12.8.10 Table Top and Height Adjustment

The following rules apply when adjusting MultiCUT/MultiCUT-HP

T = Cutting table, C = Cutting underlay
Map Table Top function is carried out on top of
the Cutting underlay.

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U = Milling underlay
The Table Top Reference function is carried out
on top of the Milling underlay

M = material to be processed
Tool Height Adjustment is carried out on top of
the actual material or on top of any other "test"
material.
Note: This adjustment can be completed
both on surface U and M (not on C), but we
recommend the described solution.

The following rules apply when milling

Mill on cutting underlay (C):
To avoid damage to the cutting underlay, the
downward movement of the drill-bit is stopped 2
mm / 0.08 inch above the cutting underlay. Thus,
it is not possible to mill through the material in
this case.
Tool height will follow the mapped tabletop.
Milling underlay (U) on top of the cutting
underlay:
To be able to mill through the material, the
thickness of the milling underlay must be > 2
mm / 0.08 inch.
If the thickness of the milling underlay (U) is < 5
mm (0.2 inches), the tool height will follow the
mapped table top.
A stiff milling underlay (S) on top of the
cutting underlay:
If the thickness of the milling underlay (S) is > 5
mm (0.2 inch), the underlay is supposed to be
more or less stiff.
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.

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12.8.11 Miscellaneous

Warm Up

Machine Panel Toolbar->Warm Up

To protect the Spindle, mandatory Warm Up is implemented.

If the Spindle has been inactive for 8 hours or more, a 3 min. Warm Up is required.
If the Spindle has been inactive for 4 weeks or more, an extended sequence is required, called Run
In.
This takes 20 minutes.

Suction House
Clean the Suction House when necessary.
Use acetone and a q-tip.
A smooth surface will ease the chip removal.

Vacuum clean the Milling Underlay

The Vacuum Cleaner can be used for automatic cleaning of the felt mat:
Prepare program to make a file that covers the actual area.
Set “bit size” to 65 mm (2.5 inch).
Hint:
• Make a file name that reflect the size used.
• Prepare Layer Setup with low spindle speed, zero depth, and maximum feed.
• Insert the Dummy Bit into the chuck.
• Adjust the brush height until the brush barely touches the mat surface.

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12.8.12 Chiller, Error Conditions

One common error signal is routed from the Chiller system to the
inverter and further into the control system.
The following error conditions are monitored:
• Temperature out of range (high and low)
• Liquid flow too low (less than 0.5 l/min). The signal is 1 minute
delayed.
• Temperature sensor failure

If any chiller failure occurs, you have to look at the chiller display to see the real reason for the problem:
Code Description
E0 Sensor failure: cable defective, connection failure, sensor defective.
IA Water level of water flow too low.
HI Temperature of cooling medium too high
LO Temperature of cooling medium too low

During normal operation, the cooling medium temperature is displayed.

More information is available from the Operating instructions for the chiller.

12.9 Measuring Foot

The Measuring Foot has 3 functions:
1. Measure the thickness of the material on the
table.
2. Map table top surface.
3. Measure the cutting underlay top level, used
as reference for tool height control.

No adjustments are necessary.

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12.10 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.

12.11 X-Pad

12.11.1 X-Pad Calibration

Note: Remove any cup or cover surrounding the tool tip during this procedure. As
a consequence, take care.

In order to work properly, the X-Pad itself must be calibrated. The following tools are applicable when
the calibration procedure is carried out:

• Ballpoint Pen

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• Drill Tool

• RM Knife

Procedure

• The calibration wizard is initiated from Option->Table Option->Calibrate Measuring Pad.

• The Measuring Pad calibration dialog appears.

• Follow the instructions in the wizard to complete calibration.

Indication that the calibration sequence is active

• A calibration sequence is indicated by:

• Continuous light in the Laser Pointer.

• Start button light is blinking.

• Pause button light is off.

12.11.2 Tool Depth and X-Pad

Be aware how X-Pad 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 Menu Bar->Advanced->Configure Tools menu.

2. The depth for a certain job is entered in Layer Setup.

12.11.3 Limitations
The following tools can be measured using X-Pad:

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Ballpoint Pen HD Crease MP HF Knife V-notch Knife

Bevel Knife HD Knife Reciprocating Knife
Crease Tool MultiCUT RM Knife
Drill Tool MultiCUT-HP

The following tools will not be measured:

Foam Knife Ink Tool MicroCut RotaCut
FoamHead KissCut Recycled Knife Static Knife

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13. Tool inserts

Knife Blades are extremely sharp.

Take care when handling Knife Tools.

13.1 Ball Point Pen

The Ball Point Pen tool is available for pen

drawing.
Tool pressure is adjustable by a knob on top of
the tool.
Ball Point Pen tool is prepared for Space Pen
refills.

Tool assembly and ressure 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.
Adjust tool pressure using the screw C.
Lock the adjustment screw using the locking
knob D.

Tool Adjustment
For this tool, complete the following adjustments:
Parameter Description
Tool Height The tool tip should touch the material surface.
Center Offset Adjust tool sideways until centered.

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Parameter Description
Tool Offset Adjust offset relative to laser pointer.

For more information about how to run the adjustment wizards, see Tool Configuration.

13.2 Bevel Knife

Bevel Knife is a special-purpose tool

for 45 degree angled cuts.

Lag = 3.5 mm / 0.14 in.

How to replace a Knife Blade

• Loosen the two screws holding the blade

clamp.
• Pull out the old Knife Blade.

• Insert the new blade.

• Ensure the blade align exactly with the
alignment pins.
• Fix the blade clamp.

At left, the clamp is removed just to show how to

align the Knife Blade.

After a blade change, the tool depth should be checked again.

How to set the cutting depth of the Bevel Knife

The default cutting depth for Bevel Knife is cut through the entire material.
Define the depth of the bevel cut in the Layer Setup.
Normally, the cut should extend down to just above the bottom liner.

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About tool adjustment
For the Bevel Knife, we recommend the manual procedures for tool rotation and centre offset
adjustment.
Use a thin Folding Carton material when adjusting tool rotation and centre offset.
Remember that you should look at the bottom side of the material for correct alignment.
The adjustments depend upon the actual material due to weight, structure and thickness.
For optimal result, a fine tuning of the adjustments in the actual material should be carried out.

13.3 Bevel Knife U20

Bevel Knife U20 is a special-purpose

tool for 20 degree angled cuts.

Lag = 1.5 mm / 0.06 in.

For proper operation, follow
instructions for Bevel Knife.

13.4 Braille Tool

Braille Tool will enable you to create signage

readable by visually impaired people.

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Braille Tool, how to add spheres

1. Keep the tool in upright position during this process.

2. Remove the cap and the plunger.
3. Pour spheres into the tool.
4. Insert the plunger and the cap. Shake the tool lightly.
5. Push the dispensing mechanism up.
6. One sphere should be pushed out from the tool

Plunger

The tool is equipped with a plunger that serves two

purposes:
1. To force the spheres into the internal funnel.
2. Indicate the number of spheres remaining in the
tool. If the groove is no longer visible it means
that there is a limited number of spheres left in the
tool.

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Braille Tool milling bit

The supplied milling bit is heavily unbalanced

and should not be run faster than 20.000 RPM to
avoid excessive wear to the milling spindle!
This also means that you should not use this
bit when warming up the milling spindle as the
warm up sequence exceeds 20.000rpm.

Braille Tool setup

In order to create high quality consistent braille patterns you should perform Tool Height and Tool
Offset calibrations.
Before adjusting offset you should set the tool height of the Braille Tool. This can be done manually
or automatically using X-Pad.

Tool Offset adjustment

Machine Connection->Tool Configuration

1 Load the Braille Tool with black spheres.

2 Cut a piece of double sided tape measuring approximately 20x20 mm / 0.8x0.8
in. and stick it to the surface of the working area. Preferably the milling underlay
or your selected substrate. It is important that the piece of tape fits within the hole
in the measuring foot with good margins.
3 Insert the Braille Tool in the MultiCUT tool head.
4 Open up the Tool Adjustment dialog.
5 Select Braille Tool and press Adjust Active Tool…
6 Select Tool Offset Adjustment and press Next.
7 Jog the tool head to the position of the tape so that the laser dot is placed in the
middle of the piece of tape.
8 Press Start. The machine will measure the material thickness and dispense a
sphere onto the tape piece.
If the Laser Spot is offset from the sphere, jog the tool head until the Laser Spot
is placed exactly on top of the sphere.

10 Click Finish and close the remaining tool adjustment dialogs.

Configure Tool

Menu Bar->Advanced->Configure Tools...

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Braille Tool should be defined with the following parameters enabled:

• Velocity Z (max speed)
• Z-axis Depth (0)
• Drill holes (on)

Preparing Layers for Braille Tool

Opened Job->Layers->Edit Layers

When making braille signage, you need two identical Layers with the braille pattern, one for milling
holes and one for inserting braille spheres.
These Layers may consist of circles or points.

Layer: Braille Drilling (MultiCUT/MultiCUT-HP)

Velocity Z
Velocity Z is material dependent and may require experimentation.
The value shown in the illustration is suitable for (and has been tested with) 3mm Dibond.
Z-axis depth
Z-axis depth is determined by the material thickness and hole depth.
It can be calculated as: Z-axis depth = hole depth – material thickness.
According to the Raster Braille manual the hole depth should be 1,07mm (0,042”).
You may find that the holes being milled are either too shallow or too deep. If so, use this parameter
to adjust to a suitable setting.
You will see this if the spheres sit too low or too high.
The standard specifies a sphere height of 0,6mm (0,023”).

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Example using 3mm Dibond: 1,07mm – 3mm = -1,93mm
Spindle RPM
Spindle RPM is material dependent and may require experimentation. The values shown in the
illustration are suitable for 3mm Dibond.
Drill holes
Drill holes check box should be enabled.

Layer: Braille Tool

Z-axis Depth
Z-axis depth should initially be set to the material thickness.
This parameter determines the pressure the Braille Tool will use to force the sphere into the hole.
If you are using soft materials and notice indentations in the material, you can lower the value to
get a lighter pressure.
On the other hand, if the spheres are not fully inserted into hard materials, like acrylic, you may
increase this value to increase the force used by the Braille Tool.
Drill Holes
Drill Holes check box must be enabled for the Braille Tool to work properly.

Creating a Braille Job file

Braille grade 1 & 2

Grade 1 braille is a letter-by-letter translation of texts.
If you wish to create Grade 1 braille signage you can use any available braille font. These fonts may
be freely available on the internet.
Grade 2 braille introduces abbreviations and contractions for a large number of commonly used
words.
This is the recommended/preferred method of creating braille texts.
For Grade 2 braille you will need dedicated translation software.
Translation software recommendations can be found in the Raster Braille manual supplied with the
Braille Tool.

Operations in the desktop publishing software

To create the Braille patterns select the Braille font and type the text.
Select a font size, which gives correct distance between the dots/patterns. Details are found in the
Raster Braille manual.
As with other fonts, outlines of the text need to be created before creating the output file for i-cut
Vision.
Since the Braille patterns should be drilled with the MultiCUT spindle as well as Braille spheres
being inserted with the Braille Tool, it is recommended to duplicate the Braille Layer.

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Keep other graphics than Braille in separate layers.

13.5 Crease Tool

Crease Tool
The Crease Tool is a multipurpose
tool allowing a wide range of creasing
wheels.

Replace crease wheel

Push the wheel into position

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13.6 Crease Tool, 60 mm

Use the ø60 mm Crease Tool to avoid
cracking the liner.

The crease wheel is attached to the tool after it

has been mounted in the Tool Head.

Note:
When working with thin materials, avoid crease
close to the Ruler.

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13.7 Drill tools

13.7.1 Flexi Drill Tool

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.
After a bit change, the tool depth should be
checked again.

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13.7.2 Reboard Drill Tool

Reboard Drill Tool is a tool insert for a standard

XL tool position.
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).
The motor RPM is adjustable from 100 - 1000,
specified in Layer Setup.
Inside one job, only one RPM is available. If
different RPMs are specified, the highest value
will be used.

How to replace a drill bit

After a bit change, the tool depth should be checked again.

13.7.3 Drill Bit dimensions

This figure shows the drill bit requirements for the tool to operate properly.

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13.7.4 Tool Adjustment

For this tool, complete the following adjustments:

Parameter Description
Tool Height The tool tip should touch the material surface.
Tool Offset Adjust offset relative to laser pointer.

For more information about how to run the adjustment wizards, see Tool Configuration.

13.7.5 Drill Tool in ArtiosCAD

ArtiosCAD has functions for Drill Tool in Sample Making, see Service Guide for ArtiosCAD –
Kongsberg integration available on the documentation DVD.

13.8 Foam Knife

The Foam Knife tool for FlexiHead is

a special purpose tool for cutting foam
materials up till 1" (25 mm).
The tool is available for all tables with
raised traverse.

Note:

• As the Foam Knife is longer than the other tools in the Tool Head, it is not possible to run the
Foam Knife tool in combination with other tools in the Tool Head.

• It is not recommended to have the Foam Knife tool in the tool position where the measuring foot
is located.

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Lag adjustments for Foam Knife
The lag for the Foam Knife tool should be
2.5mm (0.1")

How to replace a Knife Blade

Follow instructions for Static Knife.

13.9 Ink Tool

Two ink tool models are available; Liquid Ink Tool and Fibertip Tool.

13.9.1 Liquid Ink Tool

Liquid Ink Tool is for ink drawing on foil. The

tool is prepared for Staedtler 727HPK35-9 insert.

Ink tool assembly

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13.9.2 Fibertip Tool

Fibertip Tool is for ink drawing.

The tool is prepared for Staedtler Lumocolor
insert.

Fibertip tool assembly

13.10 KissCut

KissCut is a special knife tool for vinyl

cutting.
The cutting depth is controlled by the
downward knife pressure.
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.

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Description

A complete KissCut tool consist of:

A - The tool body with knife adapter
B - Pressure unit no x (two models
available)
C - Locking knob
D - Knife Blade
E - Knife foot
F - Spanner

Replace Knife Blade

This figure shows how the Knife Blade is fixed A special hand tool is available as an aid when
inside the KissCut knife tool. replacing knives. Use this hand tool when
removing and inserting knives into the tool.
The friction between the Alignment Pin A and
the Knife Blade keeps the blade in place. When inserting a new Knife Blade, ensure
the blade is correctly positioned relative to the
Alignment Pin.

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Tool pressure

Knife pressure is adjusted by turning the If higher knife pressure is needed, interchange
Pressure Adjustment knob available on top of Pressure units.
the KissCut tool.
Pressure range:
Adjust and make a test cut to obtain correct
Pressure unit #1: 0,3 - 3,5 N
setting.
Pressure unit #2: 0,8 - 7,5 N

Foot solution

Normally, the KissCut knife tool is used without

the foot mounted.
When the foot is mounted, the cutting depth d is
controlled by the adjustable screw S.

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13.11 MicroCut

The MicroCut tool is a special

purpose knife tool for applications
where exact cutting depth is required.
1 – Foot, floating on top of the material
2 – Foot pressure adjustment
3 – Depth meter. For details, see (218).
4 – Depth adjustment

How to set Cutting Depth

• When inserting a new Knife Blade,

align the tip of the knife with the
sliding sleeve and zero the depth
meter (A).

• Then adjust the micrometer screw

(Starret micrometer (218)) until
desired depth is displayed (B).
• During execution, the foot is
floating on top of the material. To
adjust the foot downward pressure,
adjust the Foot pressure screw.
• The pressure should be high
enough to ensure good contact
between the foot and the top of
the material, without scratching the
material.

Note: To secure good contact between

the foot and the top of the material,
the foot should be lifted 1 – 1.5 mm
(0.4 – 0.6 in) during execution (C). (Tool
height adjustment).

How to change Knife Blade

1. Remove the knife tool from the Tool Head.
2. Remove the sliding sleeve from the tool.
3. The Knife Blade is held by a hex-screw. A 1.5 mm key will fit.

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4. Loosen the hex-screw and insert the new blade.

5. When inserting the new blade, please make sure that:
a. The back of the Knife Blade is aligned along the reference edge of the blade socket. (To ensure
blade perpendicularity).
b. 3 mm of the blade protrudes from the blade socket (X-acto #11).
6. Tighten the hex-screws and reattach the knife tool.

13.12 Psaligraphy Knife

Psaligraphy Knife is a tool for cutting
of fine details in paper and folding
carton.

Replace Knife Blade

For Knife Blade change, remove the foot. The locking screw will always point towards the
cutting direction.
The locking screw will always point towards the
cutting direction Note: Be extremely careful when mounting the
foot.

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13.13 RBI 90-16 (Rigid Board Insert)

Insert / remove Knife Blade

Ensure the blade is correctly aligned. Use Allen Key, 3 mm, to fix / loosen the Knife
Blade.

After a blade change, the tool depth should be checked again.

Tool Adjustment
Use the standard adjustment wizards when adjusting the knife.
We recommend using a sheet of corrugated material, 5-6 mm / 0.2 inch, when executing the wizards.
Parameter Description
Lag Setting Lag = 8.5 mm / 0.33 in.
Tool Height The tool tip should touch the material surface.
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 Tool Configuration.

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13.14 Reciprocating Knife

Reciprocating Knife is available in two models:

Reciprocating Knife

Running with 6000 RPM and

amplitude +/- 0.15 mm (0.006 inches),
this tool is recommended for light duty
corrugated materials.

MP HF Knife

Running with 12000 RPM and

amplitude +/- 0.6 mm (0.024 inches),
this tool is recommended for more
demanding corrugated materials.
Note: Hearing protection is
recommended when working with this
tool.

Common to both models:

• To reduce material tear, a foot is available.
• The same set of knife adapters can be used.

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Replace Knife Blade

Pull out the electrical connection.

Note: Pull using the connector, not just the
cable.

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.

Extreme care should be taken when inserting the

knife foot again.
Keep fingers away from knife as illustrated at
left.

Tool adjustment
For this tool, complete the following adjustments:
Parameter Description
Lag Setting The knife lag depends upon the blade adapter. Nominal value is 0-3 mm.
Tool Height The tool tip should touch the material surface.
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 Tool Configuration.

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13.15 Rigid Material Knife

Insert / remove knife blade

Ensure the blade is correctly aligned. Use a 3 mm Allen Key to fix / loosen the knife
blade.

After a blade change, the tool depth should be checked again.

Tool Adjustment
Use the standard adjustment wizards when adjusting the knife.
We recommend using a sheet of corrugated material, 5-6 mm / 0.2 inch, when executing the wizards.
Parameter Description
Lag Setting The knife lag depends upon the blade adapter. Nominal value is 0-4 mm.
Tool Height The tool tip should touch the material surface.
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 Tool Configuration.

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13.16 RotaCut

RotaCut is a special tool for cutting

light materials, as thin fabric.
Maximum cutting depth is 2 mm / 0.07
inch.
Note: Due to the characteristics of this
knife tool, some restrictions apply to
the use of it:

• It is not suitable for curves with

small diameter.
• It is not suitable for designs
containing short lines in
combination with sharp angles.

The RotaCut knife tool is prepared for Decagonal Knife Blades, ø25 mm /
1 inch.

Tool adjustment

RotaCut is adjusted in the same way as the other insert tools regarding rotation angle and offset,
but tool height is manually adjusted:

Tool Height
Tool Height for RotaCut is manually
adjusted using the tool height
adjustment wizard available from the
Tool Configuration dialog.
Follow the instructions in the dialog.

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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 Tool Configuration.

How to replace the Knife Blade

Carefully put the decagonal blade onto the shaft. Ensure the blade is properly seated. Mount the
nut.

Use the spanner and the hexagonal screw driver Observe the alignment pin in the foot and the
to fix the blade properly. groove in the tool shaft.
Position the foot onto the tool shaft as shown at
left.
Note: This operation has to be carried out after
the tool insert is in place in the tool head.

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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.

Layer Setup for RotaCut

Correct setting of Lag- and Width - values are

shown.
Lag: 3.5 mm / 0.14 inch
Width: 7.0 mm / 0.28 inch

Use the Lag and Width parameters to achieve

proper corner cutting.

13.17 Static Knife

Static Knife is a multipurpose tool
allowing a wide range of Knife Blades.

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Insert Knife Blade

After a blade change, the tool depth should be

checked again.

Knife direction

The locking screw will always point towards the The locking screw will always point towards the
cutting direction cutting direction

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13.18 VI45 Knife Tool

A – knife adapter

Lag = 0mm.

How to mount VI45 Knife Tool

Remove the knife adapter from the tool and Position the tool adapter onto the shaft.
insert the upper part into the tool position.

Observe Alignment Pin orientation. Keep the knife adapter in this position while you
turn the tool shaft…

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…in order to lock the tool adapter in its position.

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14. Maintenance
More information about maintenance is available in the Maintenance Manual.

Warning
Main Power should be switched off before cleaning is carried out.

14.1 Daily maintenance

• Inspect the equipment in order to prevent any irregularities.
• The table surface should be kept clean at all times.
• The room should be cleaned regularly.
• Use a vacuum cleaner to keep the inside of the conveyor belt clean.

14.2 Weekly maintenance

The guide-ways and the bearings should be thoroughly cleaned and oiled very lightly.
The 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.

14.3 Maintenance, external equipment

All external equipment, as PC, Vacuum pump and compressor should be maintained according to
the User Manual for the actual equipment.

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15. Fuse replacement

Before starting the Fuse Replacement procedure:
• Switch Power Off using the Main Power Switch

• Remove the Main Power plug from the wall socket

15.1 MPU fuses

MPU Location

Note: MPU location is model dependent.

All fuses are located on the rear side of the Main Power Unit (MPU).

Fuse Location

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Procedure
1. Remove frame cover in front of MPU
2. Remove the metal shield covering F1/F2, F24/F48.
3. Remove one fuse, check with ohm – meter. If blown, replace with a new, identical fuse.
4. Repeat for each fuse.
5. Replace base cover.
6. Insert main power cable into the wall socket and turn main power ON

Fuse Details
Fuse location 115V 230V
F1 and F2, line fuses T 10A 250V (5x20 mm) T 5A 250V (5x20 mm)
F24, +24V fuse T 6,3A 250V (5x20 mm) T 6,3A 250V (5x20 mm)
F48, 48V Servo power fuse T 15A 250V (5x20 mm) T 15A 250V (5x20 mm)

15.2 X1 fuses

X1 Amplifier Location

Fuse Location

1 – SCU unit

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2 – 6/12A amplifier X1

Procedure
1. Remove X1 cover.
2. Check the X1 fuse with ohm - meter. If blown, replace with a new, identical fuse.
3. Replace covers.
4. Insert main power cable into the wall socket and turn main power ON.

Fuse Details
T 8A 250V 1 1/4 x 1/4 in. (6,3 x 32 mm)

15.3 X2 fuses

X2 Amplifier Location

Fuse Location

1 – 6/12A amplifier X2.

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Procedure
1. Remove X2 cover.
2. Check the X2 fuse with ohm - meter. If blown, replace with a new, identical fuse.
3. Replace covers.
4. Insert main power cable into the wall socket and turn main power ON.

Fuse Details
T 8A 250V 1 1/4 x 1/4 in. (6,3 x 32 mm)

15.4 Y/Z fuses

Y Amplifier Location

Fuse Location

1 – Y-amplifier unit
2 – TCU
3 – Z-axis motor

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Procedure
1. Remove Y cover.
2. Check the Y and Z fuse with ohm - meter. If blown, replace with a new, identical fuse.
3. Replace covers.
4. Insert main power cable into the wall socket and turn main power ON.

Fuse Details
Name Fuse
Y T 8A 250V 1 1/4 x 1/4 in. (6,3 x 32 mm)
Z T 4A 250V 1 1/4 x 1/4 in. (6,3 x 32 mm)

15.5 Tool Rotation/Reciprocating knife fuses

Fuse Location

Procedure
1. Fuses are available from beneath the Toolhead cover.
2. Remove fuse F9 or F10 and check with ohm - meter. If blown, replace with a new identical fuse.
3. Insert main power cable into the wall socket and turn main power ON.

Fuse Details
Name Fuse
F9 T 2A 250V 1 1/4 x 1/4 in (6,3 x 32 mm
F10 T 2A 250V 1 1/4 x 1/4 in (6,3 x 32 mm

15.6 Chiller fuse

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Remove the on/off button Remove cover (4 screws)

Fuse location Pull out the fuse holder

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)

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15.7 Heater for Chiller Fuse

Heater Fuse Location

The Fuse is available inside the connector cover.

Fuse details
F - 4A 250V T 5x20mm Slow Blow (42448944)

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16. Roll Feeder

A – Bracket Position Pin (push the center button to release the lock).
B – Roll Holder Bracket.
C – Brake Position Locker.
D – Roller Brake.
E – Brake Tension adjustment. Turn clockwise to increase tension.

To adapt to different roll sizes, three Roll Holder

Positions are prepared.
To move the roller bracket, remove pin (A) and
release locker (C).

To disengage the Roller Brake, release the

Brake Position Locker (C) and tilt the bracket.

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17. Collector Basket

The unit is placed in the unload end of the conveyor belt (front of table).
The unit is prepared for rigid pieces up till 200x200 mm / 8x8 in, or flexible materials.
Maximum load weight is 30 kg / 65 lbs.

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18. High-capacity Vacuum Cleaner

18.1 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 Spindle Motor damage.

18.2 Filter Shaking

Filter Shaking is important in order to maintain

a good Vacuum Cleaner performance.
Filter Shaking is best operated every time
before use and after prolonged operation.

Note: This operation must be performed only

when the Vacuum Cleaner is switched off and
the motor has stopped.

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18.3 Remove Material Container

1

Note: You can use the container with or without Plastic Bag.

18.4 Use Plastic Bag in Material Container

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Parts needed: Steel ring and plastic bag Fix the Plastic Bag to the ring in this way

Ring and Plastic Bag ready for the container Fold/fix the Plastic Bag around the container

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.

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19. High-capacity Vacuum Cleaner,

Depureco

19.1 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 Spindle Motor damage.

19.2 Filter Shaking

Filter Shaking is important in order to maintain

a good Vacuum Cleaner performance.
Filter Shaking is best operated every time
before use and after prolonged operation.

Note: This operation must be performed only

when the Vacuum Cleaner is switched off and
the motor has stopped.

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19.3 Remove Material Container

Note: You can use the container with or without Plastic Bag.

19.4 Use Plastic Bag in Material Container

Shake the filter well before emptying the Fix the Plastic Bag to the steel bar.
container.

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Plastic Bag with bar ready for container. Fold/fix the Plastic Bag around the container.
Container with Plastic Bag ready for operation.

Detailed information about how to operate the Vacuum Cleaner is available in the Operators and
maintenance manual.

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20. Vacuum Cleaner 25

1. Suction tube inlet

2. Container fixture
3. Filter unit locking mechanism
4. Motor
5. Filter unit

How to empty container

1. Ensure vacuum cleaner motor is off.
2. Remove the suction tube (1).
3. Release the container (3).
4. Remove the filter unit (5).
You should have a bucket nearby for the unit.
5. Lift and turn the container to release it from the fixture.
6. Empty the container.

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21. Install Software

For information about software installation, see the Installation Manual for the actual machine.
Available on the Documentation DVD.

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22. Frequently Asked Questions

22.1 Machine

My machine does not react when switching on

Please check electrical connection, do you have 230V? Is there enough compressed air, 7bar?
Check all main fuses in the MPU, see Fuse Replacement
Check all connections at the MCU behind the control panel
Check all connections at the start up button and the emergency buttons:

Safety system won’t reset

Make sure all sensors are aligned correctly, check the black dots on the side of the traverse
Are all transmitters pointing correctly to their receiver? Check if the red light is shining on the
receiver. If necessary, adjust by bending the transmitter/receiver holder

During start up: X1/X2/Y servo error

This is probably caused by a defect in an amplifier board. Please contact Esko for technical support

During start up: X1/X2/Y fuse error

Check the fuse of the motor
If problem persists, it is likely to be the amplifier board malfunctioning. Please contact Esko for
technical support

“Missing compressed air”

Check if you still have 7 bar at the MPU
Are the hoses not bending? Can the compressed air flow easily?
Do you hear air escaping? Check for leaks
Is the connection at the head leaking air or broken?

22.2 Tools

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After cutting, the design is difficult to remove from waste

Check tool height

After cutting, the corners are still fixed to the waste

Check tool lag

Bad quality in cutting, paper/cardboard tears

Check rotation of the tool

Offset in cut/crease lines

Check tool center offset

Offset between cut lines and crease lines

Check tool offset

Machine is milling in the carpet and table top

The milling bit is lowering inside the Chuck. Please fix the Chuck with the appropriate tool.

Milling: “Inverter not started yet”

After touching the safety unit, you need to wait for 10 seconds after resetting safety for the milling
inverter to activate
If problem persists, check the connection at the tool head of the milling spindle. Is the big green
cable still well connected?
Check all connections of the milling spindle: at tool head, inside cover X1 and at the inverter
Check serial connection between inverter and PC: connection OK? COM port changed lately?
If problem still persists, contact Esko

2 or 3 tools are working at the same time

Check your compressed air, make sure you have 7 bar
Check compressed air connection at the head. Is it well connected or is it leaking air?

Machine is milling in the milling underlay

Check vacuum zones. Are all necessary zones open? You can close non-covered areas to
strengthen the vacuum.
Check the force of the vacuum cleaner. It happens the vacuum cleaner is heightening the milling
carpets. Try to adjust the force by using the regulator on the spindle / vacuum cleaner.

22.3 iPC

iPC doesn’t want to make connection with the machine

Make sure you first switch on the machine and then iPC, not the other way around

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If there was a software update recently, check if the firmware on the machine and iPC are of the
same version
Check the serial connection between PC and MCU
Check the connection at the emergency button

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