Service Guide
i-XL
Kongsberg XL / i-XL tables
Note
We remind you that only the Esko staff, or persons having received
appropriate training, are allowed to handle, manipulate or do repairs on the system.
A Publication of: Esko-Graphics Kongsberg AS
Copyright © 1984-2013 Esko.
This copyright does not indicate that this work has been published.
All rights strictly reserved. Reproduction or issue to third parties in
any form whatever is not permitted without written authority from the publisher.
Esko reserves the right to change specifications without notice.
Esko-Graphics Kongsberg AS
www.esko.com
Document number: D3073
Status: 110905
P.O.Box 1016, N-3601 Kongsberg, Norway
Tel: +47 32 28 99 00 Fax: +47 32 28 85 15 / 32 28 67 63
not permitted without written authority from the publisher.
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i-XL Service Guide
© Copyright Esko-Graphics Kongsberg AS, Norway
All rights reserved. This material, information and instructions for use contained herein are the property of EskoGraphics 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
Kirkegårdsveien 45
N-3616 KONGSBERG
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i-XL Service Guide
Table of content
1.
INTRODUCTION ..................................................................................................................................................... 5
2.
WHAT IS I-XL COMPARED TO XL? ............................................................................................................... 6
2.1
I-CUT USER INTERFACE ......................................................................................................................................... 6
2.2
THE I-CUT COMPUTER STAND ............................................................................................................................... 6
2.3
THE I-CUT CAMERA ............................................................................................................................................... 6
2.4
MORE VACUUM SECTIONS ..................................................................................................................................... 7
2.5
PRESSURIZED AIR SUPERVISION .......................................................................................................................... 7
2.6
THE CONVEYOR BELT (OPTIONAL) ........................................................................................................................ 7
2.6.1 The belt clamps ............................................................................................................................................ 8
2.6.2 The feeder paws ........................................................................................................................................... 9
2.6.3 Vacuum reverse ........................................................................................................................................... 9
2.7
THE VINYL ROLL HOLDER (OPTIONAL)................................................................................................................ 10
2.8
THE SHEET FEEDER (OPTIONAL) ......................................................................................................................... 10
2.9
THE KISS-CUT TOOL (OPTIONAL) ....................................................................................................................... 10
3.
THE MAIN REFERENCE POINT POSITION ............................................................................................. 11
3.1
GENERAL INFORMATION ABOUT REFERENCE POINTS......................................................................................... 11
3.2
SET THE MAIN REFERENCE POINT FOR I-CUT.................................................................................................... 11
3.3
SET THE MAIN REFERENCE POINT ON A TABLE WITH RULERS .......................................................................... 12
3.3.1 If your table is running XL-Guide ........................................................................................................ 12
3.3.2 If your table is running i-Cut ................................................................................................................. 12
3.3.3 Execution ...................................................................................................................................................... 12
4.
FLEXIHEAD WITH I-CUT ................................................................................................................................. 13
5.
MULTICUT WITH I-CUT ................................................................................................................................... 13
6.
I-CUT CAMERA CONNECTION TO PC ........................................................................................................ 14
7.
I-CUT CAMERA ADJUSTMENT ....................................................................................................................... 14
8.
SOFTWARE INSTALLATION ........................................................................................................................... 15
8.1
8.2
8.3
8.4
8.5
9.
INSTALL XL-GUIDE ............................................................................................................................................. 15
INSTALL I-CUT HARDWARE AND SOFTWARE ...................................................................................................... 15
HOW TO UPDATE THE I-CUT LICENSE CODES .................................................................................................... 15
CONFIGURE XL-GUIDE FOR I-CUT CONTROL .................................................................................................... 16
CONFIGURE I-CUT FOR THE KONGSBERG I-XL................................................................................................. 16
HOW TO CHECK CAMERA OPERATION .................................................................................................... 17
10.
THE KISS-CUT KNIFE TOOL ...................................................................................................................... 18
11.
BELT TENSION .................................................................................................................................................. 21
12.
HOW TO GLUE THE BELT ............................................................................................................................ 22
12.1 INTRODUCTION .................................................................................................................................................... 22
12.2 BELT GLUE PROCEDURE, NOVEMBER 05, 2007 ............................................................................................... 22
12.3 OLD BELT GLUE PROCEDURE ............................................................................................................................... 28
12.3.1 Tools you need ....................................................................................................................................... 28
12.3.2 Procedure ................................................................................................................................................. 29
13.
SHEET FEEDER .................................................................................................................................................. 35
13.1
13.2
13.3
13.4
14.
SHEET FEEDER POSITION .................................................................................................................................... 35
SHEET FEEDER USB TO SERIAL LINE SETUP...................................................................................................... 35
SHEET FEEDER SETUP .......................................................................................................................................... 35
SHEET FEEDER LOAD TABLE BRACKETS.............................................................................................................. 36
AIR AND VACUUM, BLOCKED SCHEMATIC ....................................................................................... 38
14.1
PRESSURIZED AIR LAYOUT WHEN SHEET FEEDER IS INSTALLED ...................................................................... 38
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14.2 ONE VACUUM PUMP, TWO VACUUM SECTIONS ................................................................................................... 39
14.3 TWO VACUUM PUMPS (OPTIONAL) ...................................................................................................................... 40
14.3.1 General ...................................................................................................................................................... 40
14.3.2 3 sections ................................................................................................................................................. 40
14.3.3 4 sections ................................................................................................................................................. 40
15.
ELECTRICAL CONNECTIONS FOR CAMERA, BLOCKED SCHEMATIC ................................... 41
16.
ELECTRICAL SCHEMATICS ......................................................................................................................... 42
16.1 TABLE CONNECTIONS .......................................................................................................................................... 42
16.1.1 i-XL el. schematic .................................................................................................................................. 42
16.1.2 Sheet feeder connections, details ................................................................................................... 42
16.1.3 Pressurized air sensor, details .......................................................................................................... 42
16.1.4 i-XL-20 cable overview ........................................................................................................................ 42
16.1.5 i-XL-24 cable overview ........................................................................................................................ 42
16.1.6 i-XL-44 cable overview ........................................................................................................................ 42
16.2 SHEET FEEDER ..................................................................................................................................................... 42
16.2.1 Power and safety relay ...................................................................................................................... 42
16.2.2 Motor / drive wiring .............................................................................................................................. 42
16.2.3 PLC & I/O .................................................................................................................................................. 42
16.2.4 I/O ............................................................................................................................................................... 42
16.2.5 I/O ............................................................................................................................................................... 42
16.2.6 Enclosure .................................................................................................................................................. 42
17.
MECHANICAL DRAWINGS .......................................................................................................................... 43
17.1
17.2
17.3
17.4
17.5
17.6
17.7
17.8
17.9
18.
I-XL20 W/ CONVEYOR ........................................................................................................................................ 43
I-XL20 W/
2 VACUUM SECTIONS ...................................................................................................................... 43
2 SECTIONS AND VACUUM REVERSE .............................................................................................. 43
I-XL24 W/ CONVEYOR ........................................................................................................................................ 43
I-XL24 W/ 3 VACUUM SECTIONS ...................................................................................................................... 43
I-XL24 W/ 3 SECTIONS AND VACUUM REVERSE .............................................................................................. 43
I-XL44 W/ CONVEYOR ........................................................................................................................................ 43
I-XL44 W/ 3 VACUUM SECTIONS ...................................................................................................................... 43
I-XL44 W/ 3 SECTIONS AND VACUUM REVERSE .............................................................................................. 43
I-XL20 W/
APPENDIX 1 – I-CUT PRODUCTION SETTINGS FOR KONGSBERG ..................................... 44
19.
APPENDIX 2 – HOW TO VERIFY AND ADJUST CORRECT ANGLE ON A TABLE WITH
CONVEYOR BELT........................................................................................................................................................... 45
20.
APPENDIX 3 - FIELD INSTALLATION OF CONVEYOR BELT PAWS AND CLAMPS ....... 47
20.1
20.2
20.3
20.4
20.5
21.
PRESSURIZED AIR CONNECTIONS, BLOCKED SCHEMATIC................................................................................. 47
HOW TO PUT ADDITIONAL CABLES INTO THE TRAVERSE BEAM ........................................................................ 48
REAR SIDE OF TRAVERSE, ASSEMBLY ................................................................................................................. 51
FEEDER CLAMP, X1, ASSEMBLY .......................................................................................................................... 53
FEEDER CLAMP, X2, ASSEMBLY .......................................................................................................................... 53
APPENDIX 4 - REVOLVING WORK STATION, ASSEMBLY PROCEDURE ............................ 54
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i-XL Service Guide
1. Introduction

What is i-XL compared to XL?

What are the mechanical differences?

What are the electrical differences?

What about software?

How do I operate i-XL?
The intention of this manual is to answer such questions.
It is aimed especially for Esko-Graphics service personnel.
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2. What is i-XL compared to XL?
The main differences introduced by i-XL compared to XL are:
2.1
i-Cut user interface
The system use i-Cut as user interface. i-Cut is a software package delivered by Mikkelsen Graphic
Engineering, inc (MGE), a company sited in Lake Geneva, Wisconsin.
I-Cut
XL-Guide
Front End PC
Cutting Table
The i-Cut software and the XL-Guide software are both installed and running on the front-end PC.
A command protocol is established between i-Cut and XL-Guide, allowing commands from i-Cut to
be executed in XL-Guide. But it is XL-Guide that actually runs the table. You can run XL-Guide as
normal if i-Cut is terminated.
2.2
The i-Cut computer stand
To allow for the conveyor belt, the standard front panel on XL has been replaced by an i-Cut
computer stand. The stand is fixed to the i-XL table frame, close to the –X,-Y – corner of the table.
The i-Cut computer stand includes the following components:
 An XP pc delivered from Shuttle with keyboard and mouse. The keyboard is a dedicated
model built into the top of the stand.
 A flat-screen monitor for the pc.
 A complete MCU – unit including a standard XL operator panel. The only difference is that the
operator panel and the MCU–unit are separated; the panel is glued on top of the i-Cut table
while the MCU–unit is mounted beneath the table.
 Power on and Emergency stop buttons
It is possible to rotate the top of the i-Cut stand +/-90o. From XL-Guide, it is possible to modify the
orientation of the jog buttons on the operator panel to correspont to the actual orientation of the
panel.
2.3
The i-Cut camera
One key function in i-Cut is the possibility to read register marks.
A video camera inside the tool head is connected to a video grabber card inside the front end PC.
In addition to the camera itself, a light unit is mounted in front of the camera.
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Currently, the FlexiHead and MultiCut tool heads are prepared for the i-Cut camera.
You will find more details in chapter 5, 6 and 7.
2.4
More vacuum sections
Depending upon the model type, an i-XL table will have more vacuum sections compared to
standard XL.
2.5
Pressurized air supervision
To avoid damage due to missing or too low air pressure, a sensor is located beneath the cutting
table.
If the pressure level for the pressurized air is below a certain limit, machine execution is stopped
and an error message is displayed. The sensor is connected to the air tube for traverse and tool
control.
The input from the sensor is read by an analogue input on SCU.
2.6
The conveyor belt (optional)
The i-XL table can be equipped with a conveyor belt. With the conveyor belt, you can feed material
into and out from the working area on the cutting table.
The pulling force is approximately 400N.
Adjustable
Adjustable
Adjustable guides
The belt itself is a specially prepared conveyor belt.
The picture above shows how the belt is moving around rollers mounted on both sides of the table
and the table frame.
One or more rollers inside the table frame prevent the belt from touching the floor.
When shipped from Kongsberg, the belt is rolled up in a separate roll. During installation, you have
to mount the belt onto the table and glue it together. You will find a detailed description on how to
glue the belt in chapter
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The picture at left shows how to mount
the belt on large tables, as i-XL24 and
i-XL44.
Two different air cylinder systems are used to grab the belt and move it forward. Both systems are
mounted onto the traverse, as it is the traverse that actually moves the belt forward:
2.6.1 The belt clamps
One clamp on
each side
grabs the belt
and moves it
forward.
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2.6.2 The feeder paws
Four feeder paws pushes the material
down towards the conveyor belt. In
this way the material is fixed and kept
in place during the belt movement.
The position of the feeder paws along
the Y-axis is adjustable. To release or
lock, a locking knob is available.
It is also possible to disable the
operation of a paw by closing the air
switch to the paw (the blue handle).
It is a general rule that at least two
paws should be inside one sheet of
material.
The air pressure to the two air cylinder systems is adjustable. Maximum pressure should be applied
to the belt clamp.
The pressure to the feeder paws should be kept as low as possible, as increased pressure increases
the friction between the belt and the table.
2.6.3 Vacuum reverse
In order to minimize the friction between the conveyor belt and the cutting table, an air blow is
creating an air pillow below the belt during the belt movement.
Two vacuum valves and a fan provides the air pillow as illustrated:
FAN
Vacuum ON
PUMP
FAN
Vacuum reverse ON
PUMP
During normal operation, the valve to the fan is closed while the valve to the vacuum pump is open.
In this case, you have vacuum on the cutting table.
When the valve to the fan is open and the fan to the vacuum pump is closed, you have an air blow
out from the tabletop.
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2.7
The vinyl roll holder (optional)
A roll holder for vinyl rolls is available.
The distance between the rolls can be changed
to suit different roll sizes.
Roll diameters up to ø200 mm is possible.
Note: The weight of the roll has to be
considered. If heavy weight, the acceleration of
the belt movement should be reduced.
Reduced acceleration is also recommended to
avoid material spin-off.
2.8
The sheet feeder (optional)
MGE offers a sheet feeder that can be mounted on the rear side of the cutting table.
You can load a stack of material into the sheet feeder. The feeder will lift one and one sheet onto
the cutting table where the conveyor belt system moves the material into the working area of the
machine.
The interface between the sheet feeder and the i-XL table is just one control signal.
In addition, there is an USB – connection between the sheet feeder and the front end PC.
2.9
The kiss-cut tool (optional)
The kiss-cut tool was developed as part of the i-XL, but the tool is also available for XL. The kiss-cut
tool is a special tool for vinyl cutting. You will find a detailed description of the tool and how to use it
in chapter 8.
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3. The Main Reference point position
3.1
General information about reference points
Working
area
Y
X
Main reference point
All X- and Y co-ordinates in the Input program file use the selected reference point as its origin.
Two modes are available:
1. Fixed reference point – the position of the reference point is fixed on the table.
2. Panel reference point – the position of the reference point is set by pressing the Init push button
on the Operator panel.
The fixed reference point number 1 is defined to be the Main reference point.
The Main reference point has to be correctly positioned in order to obtain:
 A full working area.
 Correct sheet feed operation.
 Correct handling of long jobs
 Using the Main reference point during program execution ensures correct operation.
3.2
Set the Main reference point for i-Cut
If you are about to run i-Cut on your table, use this procedure to set the Main reference point:
1. Go to Option, Table setup, Set Reference point.
2. Press the i-Cut Main Reference - button. The Main reference point is correctly positioned.
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3.3
Set the Main reference point on a table with rulers
3.3.1 If your table is running XL-Guide
10 mm/0.4 inch
Ruler
Main reference point
The Main reference point is set 10 mm / 0.4 inches inside the ruler in both axes:
1. Go to Option, Table setup, Set Reference point.
2. Select reference point 1 and follow the instruction on the screen.
3.3.2 If your table is running i-Cut
I-Cut reference point =
Main reference point
Reference point 2
Unfortunately, the Main reference point for i-Cut and XL-Guide are in different positions on the table.
In order to run both i-Cut and XL-Guide on the same table, we have to follow these rules:
1. The Main reference point on the table (Ref. point 1) is set using the i-Cut Main Reference button as described above. Do not modify the position of Reference point 1 after this initial
setting.
2. As reference point when running XL-Guide select any of the other reference points available, for
instance Reference point 2. Go to Option, Table setup, Set Reference point.
Select reference point 2 and follow the instructions on the screen to set reference point 2 10 mm
/ 0.4 inches inside the ruler.
3.3.3 Execution
After the initial setup, follow these rules:
1. When running i-Cut, select reference point 1 on the table.
2. When running from XL-Guide, select reference point 2 on the table (or the reference point you
selected during setup).
Note: The working area for i-Cut is somewhat smaller compared to the working area for XL-Guide.
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4. FlexiHead with i-Cut
I-Cut
camera
5. MultiCut with i-Cut
I-Cut
camera
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6. i-Cut Camera connection to PC
A Pixci Sv5 Imaging
Board is installed in the
front-end pc.
The video cable is
connected as shown at
left.
A separate +12V power
supply provides power
to the camera and the
light unit.
7. i-Cut camera adjustment
Two adjustments are available:
A - adjust the aperture.
F - adjust camera focus.
Note:
When adjusting the i-Cut camera on MultiCut, the adjustment knobs are available in between the
knife foot, as illustrated in the picture above.
Before any adjustments are carried out, remove the knife from this tool position.
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8. Software installation
8.1
Install XL-Guide
Insert the XL-Guide CD in the Front end PC. From the XL-Guide CD, start Setup.exe. Follow
instructions on screen and install in default directories.
You will find more information about software installation in the XL-Guide online help manual.
8.2
Install i-Cut hardware and software
Before installation of i-Cut software can begin, you must complete the following:
1. Install the Epix PIXCI Video Capture Board into an unused PCI slot in your computer.
2. Connect your i-Cut dongle to an available USB port. Two dongles are included in the delivery,
one for production preparation and one for cutting table control. On the Front end PC, the
cutting table control dongle should be used.
3. Connect the plotter and vision system to your computer.
4. Log onto your Windows® operating system administrator account.
5. Insert the i-Cut installation disc into your CD-ROM compatible drive.
Installing i-Cut requires adding the following three software components to your system:
1. Epix PIXCI Video Capture Board Driver
2. HASP copy protection support
3. i-Cut main program
You will find more details regarding software installation in the i-Cut User‟s manual.
8.3
How to update the i-Cut license codes
From PC Desktop or Start menu, start i-Cut.
From the Options menu, select –Configuration:
The options available from the license defined by current dongle are listed in this dialog.
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If a license update is needed, copy and paste the new control word into the edit box below and press
the Add button.
Restart i-Cut to enable the updated license.
8.4
Configure XL-Guide for i-Cut control
Ensure the following XL-Guide settings are valid:
Parameter
Set from
Setting
Optimize
Options/System options
Disabled
Sequencing
Options/System options
Disabled
i-Cut controlled vacuum
Options/System options
Enabled
Main ref point no 1
Options/Table options/Set reference point
Ref.pt. no 1
i-Cut Main Reference
Options/Table options/Set reference point
Execute
Single/multiple design
Main toolbar
Single design
8.5
Configure i-Cut for the Kongsberg i-XL
From PC Desktop or Start menu, start i-Cut.
Note: After start-up, i-Cut is waiting until the table zero sequence on the table is completed.
Therefore, press Start to execute the sequence.
From the Options menu, select –System:
From the “Plotter Type” drop down menu, select the proper Kongsberg table.
Ensure the following i-Cut settings are valid:
Parameter
Kongsberg tool bar
Set from
Wiev
Setting
Enabled
More information about system setup is available in the i-Cut User‟s manual.
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9. How to check camera operation
Proceed as follows:
1. From PC Desktop or Start menu, start i-Cut.
2. Observe XL-Guide is started.
3. Switch servo on and complete the Table zero sequence
4. From the i-Cut Calibration menu, select –Check Regmark.
5. A window showing the camera picture appears. Sometimes you have to open the window
from the task bar:
Adjust the camera aperture and focus until you have a light picture with focus as sharp as possible.
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10. The kiss-cut knife tool
A complete kisscut tool consist of:
A - The tool body
B - Knife adapter
C - Locking knob with Pressure unit #1
D - Knife foot
E - Knife
F - Pressure unit #2
G - Spanner
The picture at left shows how to insert the
knife into the knife adapter.
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Use the spanner to push the knife into the
adapter.
Use the spanner also when pulling out the
knife from the adapter.
The picture shows the knife properly
mounted.
Now the knife tool is ready to use.
The knife depth is controlled by knife
pressure.
If you need exact control of knife depth,
use the knife foot as illustrated at left.
The depth is controlled by the foot position
relative to the knife. Turn the foot to
adjust.
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Knife pressure is adjusted by turning the
Pressure unit knob available on top of the
KissCut tool.
Adjust and make a test cut to obtain
correct setting.
If higher knife pressure is needed,
interchange Pressure units.
Pressure range:
Pressure unit #1: 0,3 - 3,5 N
Pressure unit #1: 0,8 - 7,5 N
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11. Belt tension
Adjustable
Adjustable
Adjustable
Adjustable
The position of the conveyor belt rollers is adjustable:
- Adjust the upper rollers to be parallel to the tabletop.
- Use the lower rollers for belt tension adjustment. As the adjustment span is limited, it is
important you position the rollers in a „middle‟ position before gluing the belt.
Belt tension
It is difficult to give an exact advice
for belt tension. The illustration at
left shows that a relative high belt
tension is recommended.
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12. How to glue the belt
12.1
Introduction
For belt glue, two different procedures are available. If possible, we recommend the procedure
introduced November 05, 2007.
12.2
Belt glue procedure, November 05, 2007
Compared to the previous procedure, this is a simplified method where the belt is cut at an angle
and glued in one operation.
The cut angle and distances are found in this figure 1:
i-XL4x, w=2270 mm/89.4 inch
i-XL24, w=1740 mm/68.5 inch
i-XE32, w=1360 mm/53.5 inch
i-XE10, w=960 mm/37.8 inch
22-23 o
398
563
720
940
mm/16
mm/22
mm/28
mm/37
inch
inch
inch
inch
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Required tooling:
Glue applicator (3M EPX, 42446039)
Glue tube with nozzles (3M DP-110,
42446021 and nozzle 42446351).
Sharp knife
2” wide tape
Measuring tape
Sand paper
Protective gloves
Safety glasses (42429050)
Note: Glue 3M DP-105 is an
acceptable alternative to DP-110.
A complete set is available as:
02737781 Conveyor belt repair kit
One glue tube with two nozzles is
available as:
02737872 Conveyor belt glue pack
Assemble the glue applicator:
1 – Insert the plunger
2 – Mount the glue tube.
3 - Remove the cap from the glue tube.
4 – Remove any sealing.
5 – Mount the nozzle
6 – Purge the nozzle
Note:

Use protective gloves when handling the glue.

Use safety glasses; avoid any contact between glue and eyes.

Avoid direct contact or inhale of glue.
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Procedure:
Smooth in this direction
Belt moving direction
Cutting table
+X
You can observe that
the belt has low friction
when moving your
hand on top of it in one
direction and high
friction when moving
the opposite direction.
It is important the belt
is mounted onto the
table in the indicated
orientation.
Move all rollers to the
inner position before
the belt is mounted. In
this way, you have the
possibility to increase
the tension after
mounting.
Roll out the belt onto
the table.
The belt should not be
too tight and not too
loose.
The picture shows how
the belt is hanging
between the rolls
beneath the table
frame.
Put a sheet of material beneath the belt,
preparing for the knife cut.
Ensure correct belt tension.
If the belt is delivered at the correct
length, check the belt tension and cut the
belt if necessary.
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Use tape or heavy weight to keep the belt
in position.
Measure the relevant distances as
illustrated in figure 1 and place a ruler
along the cut path.
Use a sharp knife to cut through both belt
materials.
Remove waste material and the cutting
underlay.
3 mm (1/8 inch)
Pull the belt parts apart until there is a
gap of 3 mm (1/8 inch).
From the bottom and up, apply a tape
beneath the belt in order to:

Keep the belt together.

Prevent gluing the belt to the table
top.
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On both sides, the edge of the belt joint
should be smoothly rounded as illustrated
at left.
Apply glue to the gap. Make sure you
have a round top above the belt surface.
Note:

Use protective gloves when
handling the glue.

Use safety glasses; avoid any
contact between glue and eyes.

Avoid direct contact or inhale of
glue.
Make sure to discard the nozzle and
replace the cap on your adhesive.
Apply tape on top of the glue.
By hand, rub the surface of the tape until
it is flat and even.
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Put a hard, flat material on top of the belt
splice.
Add some heavy weight.
Wait minimum 2 hours for the adhesive to
harden.
Remove the load and the tape.
If necessary, sand the top of the adhesive
until the surface is smooth and flat.
Pay special attention to the edges.
Ensure the belt edges are smooth and
without sharp edges.
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12.3
Old belt glue procedure
12.3.1 Tools you need
1 Milling motor
2 Milling bit, square, 4 mm (see picture at
left)
3 Wrenches for the motor chuck
4 Holder for milling motor
5 Superglue
6 Glue gun for melted glue
7 Glue for glue gun
8 Sanding paper
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12.3.2 Procedure
Smooth in this direction
Belt moving direction
Cutting table
+X
You can observe that the belt
has low friction when moving
your hand on top of it in one
direction and high friction when
moving the opposite direction.
It is important the belt is
mounted onto the table in the
indicated orientation.
Roll out the belt onto the table.
The belt should not be tight.
The picture shows how the belt
is hanging between the rolls
beneath the table frame.
Mount the belt onto the cutting table, with ends overlapping.
Ensure the belt is parallell to the table edges.
Use application tape to secure the belts position on the table.
Cut both ends of the conveyor belt in exactly 90o, with a straight
and clean cut.
Place the two belt ends above
each other on a piece of cutting
underlay.
Use adhesive tape to keep the
belt in a stable position.
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Use a straight ruler as a guide
when cutting the two belt ends.
With adhesive tape, fix one end
of the belt.
Place an adhesive tape on the
table with the adhesive side up
as shown.
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Put half of the tape beneath the
fixed belt end. Fix the tape.
Pull the two belt ends together
and fix them with the tape.
Use adhesive tape to keep the
belt in position.
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Use a Router with a straight
router bit, ø4 mm / 0,16 inch.
The gap around the bit should
be as small as possible to avoid
belt material moving up.
Make a test cut on a spare piece
of belt material.
The path should go almost
halfway through the belt.
Note: It is important the
centerstructure of the belt is
kept undamaged.
Use the straight ruler as an aid
when milling a path in the belt
material.
The path should be centered on
the belt edges.
Use a sanding paper to clean the
path.
Use a vacuum cleaner to
remove dust and particles from
the path.
Use Super Glue to glue the two
ends of the belt together.
The glue should flow down and
fill the belt structure all way
through.
Wait one hour to allow the glue
to harden.
Use a sanding paper to round
the edges.
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Use the Router once more to
remove glue and prepare a
clean path.
Use a vacuum cleaner to
remove dust and particles from
the path.
Fill the path with glue using a
hot melt gun.
Use a flat and sharp knife to
remove superflous glue.
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Use a sanding paper to
smoothen the glue surface and
make it even with the belt
material around.
Pay special attention to the
edges.
Ensure the belt edges are
smooth and witout sharp edges.
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13. Sheet feeder
13.1
Sheet feeder position
Feeder
paw
Sheet feeder
suction
cup
Material
Cutting
table
This figure illustrates how the feeder paws, the suction cups and the material should meet
in order for the paws to grab the material without any collision with the sheet feeder.
13.2
Sheet feeder USB to serial line setup
Settings for the serial connection between the PC and the Sheet feeder is:
9600 baud, 8 bit, Odd parity, No flow control.
13.3
Sheet feeder setup
Parameter ( sheet feeder panel )
Setting
Horizontal Lift Jog:
Off
Horizontal Lift Enable for Auto:
Yes, if using Level Lift option, No otherwise
Horiz. Lift Move Forward At Release Time:
6 seconds
i-Cut Communication:
On
Rollback Distance:
15 mm
Pick Pause Distance:
25 mm
Number of Pick Attempts:
3
Drive Current Limit Raising:
50%
Drive Current Limit Travers:
50%
Drive Current Limit Lower:
50%
Pick Vacuum Low Set Point:
-100 mm HG
Standby Position:
-275 mm
Force Vacuum:
Off
Release Air:
Off
Separator Air:
Off
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Parameter ( sheet feeder panel )
Setting
Pick Additional Travel:
0 ms
Hold Length At Pick Time:
3 seconds
Carriage Position:
2 mm
For optimising of performance to various materials etc, adjustments might be required. For
description of each setting, see Sheet Feeder Operators Manual
13.4
Sheet feeder Load table brackets
These pictures show how to use the table
brackets to create a container suitable for the
stack of material.
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Picture at left: To release the fixture, push the
locking pin.
Pictures below: Mount the air knives in front of
the stack of material in order to improve sheet
separation.
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14. Air and vacuum, blocked schematic
14.1
Pressurized air layout when sheet feeder is installed
Wall
outlet
From customer
12174413
12702205
12174447
42443002
42445742
Cutting
table
Sheet
Feeder
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14.2
One vacuum pump, two vacuum sections
Vacuum pump
Foil feed
To sheet feeder
Vacuum reverse
1 5
3
4
2
Vacuum sect. 1
Front
+48V servo on
controlled
Vacuum area 1
Vacuum sect. 2
Pressurized
air, 7 bar
1 5
3
4
2
Air Pressure Sensor
Switch on when pressure > 4 bar
Feeder paws down
3
1
5
2(B)
4(A)
Feeder paws up
Feeder paws down
3
1
5
2(B)
4(A)
Belt Clamp
Belt clamp on
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14.3
Two vacuum pumps (optional)
14.3.1 General
14.3.2 3 sections
14.3.3 4 sections
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15. Electrical connections for camera, blocked schematic
Coax for camera
1
115-230V
+12V
PS
3 11 10 12 7
4
5
6
1
4
2 3
Ca
me
ra
Carriage
41
3 2
outlet,
front view
1, 2 = 12V
3, 4 = GND
Mains
power
on/off
9
8
2
LED
power
4 = 12V
1 = GND Light Unit
12V
0V
Camera
power
12 = 12V
11 = GND
+24V
Feeder Paws Down
SCU DO 09
Belt Clamp On
SCU DO 02
SCU DO 04
Vacuum reverse
Vacuum reverse
Start weeder
SCU DO 05
0V
SCU DI 02
Foil Feed
Release sheet feeder
Sheet feeder conn.
+24V
Glue Applicator
(FlexiHead)
TCU DO 06
MPU
+48V (Servo on controlled)
Air pressure fan
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16. Electrical schematics
16.1
Table connections
16.1.1 i-XL el. schematic
16.1.2 Sheet feeder connections, details
16.1.3 Pressurized air sensor, details
16.1.4 i-XL-20 cable overview
16.1.5 i-XL-24 cable overview
16.1.6 i-XL-44 cable overview
16.2
Sheet feeder
16.2.1 Power and safety relay
16.2.2 Motor / drive wiring
16.2.3 PLC & I/O
16.2.4 I/O
16.2.5 I/O
16.2.6 Enclosure
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17. Mechanical drawings
17.1
i-XL20 w/ conveyor
404440
17.2
i-XL20 w/ 2 vacuum sections
404525
17.3
i-XL20 w/ 2 sections and vacuum reverse
404290
17.4
i-XL24 w/ conveyor
404445
17.5
i-XL24 w/ 3 vacuum sections
404526
17.6
i-XL24 w/ 3 sections and vacuum reverse
404435
17.7
i-XL44 w/ conveyor
404515
17.8
i-XL44 w/ 3 vacuum sections
404517
17.9
i-XL44 w/ 3 sections and vacuum reverse
404513
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18. Appendix 1 – i-Cut production settings for Kongsberg
This is just one sample to show how to control vacuum and blow back in a manual operation setup.
I-FM 0/1 – Sheet feed communication
%PMPon/off – starts / stops the vacuum pump
%SUCon/off – controls whether we have suction or blow back (%SUCoff == blow back)
I-PK – park
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19. Appendix 2 – How to verify and adjust correct angle on a table
with conveyor belt
On machines without conveyor belt, a set of vacuum holes is used as reference when checking the
traverse angle.
On machines with conveyor belt, the vacuum holes are hidden beneath the belt. This procedure
describes one method to verify and adjust the angle:
Cutting table
Put a sheet of material on the
cutting table.
Switch vacuum on.
Keep the vacuum on during the
execution of this procedure.
+Y
+X
B
Execute the following file found in
the IAT directory:
i-XE10: AngleCut10.acm
i-XL24: AngleCut24.acm
i-XL44: AngleCut44.acm
Run with a knife and cut through
the material.
While the vacuum is still on,
carefully remove the inner parts as
illustrated.
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Turn sheet B and insert it into the
space as illustrated at left.
B
d d
If the angle is out of adjustment as
illustrated at left, use the two red
spots as reference when executing
the Angle adjust wizard.
B
Laser spot
If the angle is out of adjustment the
opposite way as illustrated at left,
use the two red spots as reference
when executing the Angle adjust
wizard.
B
When the angle is correctly
adjusted, the two cuts should align.
B
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20. Appendix 3 - Field Installation of Conveyor belt Paws and
Clamps
20.1
Pressurized air connections, blocked schematic
Vacuum pump
Foil feed
To sheet feeder
Vacuum reverse
1 5
3
4
2
Vacuum sect. 1
Front
+48V servo on
controlled
Vacuum area 1
Vacuum sect. 2
Pressurized
air, 7 bar
1 5
3
4
2
Air Pressure Sensor
Switch on when pressure > 4 bar
Feeder paws down
Press.
regulator
3
1
5
2(B)
4(A)
Feeder paws up
Feeder paws down
3
1
5
2(B)
4(A)
Belt Clamp
Belt clamp on
Press.
regulator
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20.2
How to put additional cables into the traverse beam
1
1 – traverse beam with air
tube.
2
2 – cut the air tube as
indicated.
3
3 – fix a string to the air tube.
4
4 – put the string through the
traverse by pulling the air tube
out
5
5 – Fix the two additional
cables together with the air
tube to the string.
6
6 – Pull the string and drag the
cables and the air tube into the
traverse beam.
7 – suddenly, you have both
the air tube and the cables in
place.
7
For some pictures, see next page.
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String fixed to the air
tube.
Pull the air tube out in
order to pull the string
through the traverse
beam.
Fix cables to the
string.
Ready to be pulled
into the traverse
beam.
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Pull the string to move
the cables into the
traverse.
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20.3
Rear side of traverse, assembly
View nearest to X2 –
end of traverse.
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View nearest to X1 –
end of traverse.
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20.4
Feeder clamp, X1, assembly
20.5
Feeder clamp, X2, assembly
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21. Appendix 4 - Revolving work station, assembly procedure
If not available, drill the fixture holes in
the frame beam.
Fixture hole information:
D
L = 120 mm / 4.72 inches.
W = 258 mm / 10.16 inches.
D = 2 x ø9.0 mm / 0.35 inches.
L
W
Assemble the frame bracket as shown at
left.
Fix the frame bracket to the frame.
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The next sub-assembly is the pc housing.
The picture shows the parts included.
Insert the screws as shown.
Mount the side brackets to the housing.
The side brackets should align with the
top of the pc housing.
Fix the brackets in this position.
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Mount the pc housing on the frame
bracket.
Fix the housing to the frame bracket using
8 screws.
Put all cables for the operator panel,
keyboard, screen, mouse, ON/OFF switch
and Emergency stop switch in between
the side brackets.
Ensure you have all cables in place before
continuing. If you miss one, you have to
repeat from here.
Mount the foot onto the beam as shown.
In the upper right corner picture, you see
the T-slot nut.
Insert two nuts into the slots in the beam.
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Raise the beam towards the pc housing
and fix it using one T-slot nut entered
from above.
Ensure the beam is exactly vertical.
If not, loosen the T-slot nut carefully and
adjust the beam until perfect.
Then fix the beam to the pc housing using
all four T-slot nuts.
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Fix the top disk to the beam as shown.
It should be possible to turn the disk
afterwards.
Therefore, leave the screws with a tiny
gap.
Lock the screws using Loctite 243.
Fix the top frame to the top disk.
Mount all cables for MCU, switches,
screen, keyboard and mouse nicely from
the beam and up.
Internal cabling.
Mount the plastic cover and fix it to the
top frame.
Place the pc screen onto the work station
and fix it with the fixture as shown.
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Assemble the cables in a nice way
beneath the top frame.
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