3090InstallationMan XP

Installation Manual
for
Kongsberg XP tables
Note
We remind you that only the Esko staff, or persons having received
an appropriate training, are allowed to handle, manipulate or do repairs on the system.
A Publication of: Esko

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.
EskoKongsberg AS
www.esko.com
Document number: D3090

Status: 131018
P.O.Box 1016, N-3601 Kongsberg, Norway

Tel: +47 32 28 99 00 Fax: +47 32 28 85 15 / 32 28 67 63
XP Installation manual
Change record
Date
By
Description
06-09-2011
jhbe
Expak tool for clips added
05-01-2012
jhbe
Router serial line setup added
21-06-2012
jhbe
HPMU added
03-07-2012
jhbe
HSMU/HPMU gallows suction tube assembly modified
10-07-2012
jhbe
Vacuum tubing chapter has been updated
13-07-2012
jhbe
HPMU el. schematics updated
31-08-2012
jhbe
HP PC fixture added
12-03-2013
jhbe
HPMU chiller without heater introduced.
18-03-2013
jhbe
Emphasize the importance of fixed connectors.
19-03-2013
jhbe
HPMU gallows tension adjustment added
27-03-2013
jhbe
Installation on 32/64 bit PC, chapter added
18-03-2013
jhbe
Document is adapted to the Standard Work Flow.
Copyright Esko
All rights reserved.
This material, information and instructions for use contained herein are the property of Esko. There are no
warranties granted or extended by this document.
Furthermore Esko does not warrant, guarantee or make any representations regarding the use, or the results of
the use of the system or the information contained herein.
Esko shall not be liable for any direct, indirect, consequential or incidental damages arising out of the use or
inability to use the system or the information contained herein.
The information contained herein is subject to change without notice. Revisions may be issued from time to time to
advise of such changes and/or additions.
No part of this system may be reproduced, stored in a data base or retrieval system, or published, in any form or
in any way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written
permission from Esko.
This document supersedes all previous dated versions.
Correspondence regarding this publication should be forwarded to:
Global Support
Esko-Graphics Kongsberg AS
Kirkegrdsveien 45
N-3616 KONGSBERG
Table of content
1.
TABLE INSTALLATION .............................................................................................................................................. 6

1.1
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
1.14
1.15
1.16
1.17
1.18
1.19
1.20
1.21
1.22
1.23
1.24
1.25
1.26
1.27
1.28
1.29
1.30
1.31
1.32
1.33
1.34
1.35
1.36
1.37
1.38
1.39
1.40
1.41
1.42
1.43
1.44
1.45
1.46
1.47
1.48
1.49
1.50
1.51
2.
INTRODUCTION ............................................................................................................................................................ 6
SPECIAL TOOLS ............................................................................................................................................................ 7
TABLE INSTALLATION SEQUENCE ................................................................................................................................ 7
INSPECT THE EQUIPMENT ............................................................................................................................................ 8
INSPECT THE CUSTOMERS SITE PREPARATION ......................................................................................................... 8
REQUIREMENTS FOR ACCEPTANCE TEST..................................................................................................................... 8
DECIDE WHERE IN THE ROOM TO LOCATE THE SYSTEM ............................................................................................ 8
DECIDE SPACE FOR TEMPORARY STORAGE................................................................................................................. 9
VERIFY ACCEPTABLE FLOOR LEVEL.............................................................................................................................. 9
MOVE THE CRATES INTO THE ROOM ........................................................................................................................... 9
UNPACK EQUIPMENT .................................................................................................................................................... 9
BOX ORIENTATION ....................................................................................................................................................... 9
UNPACKING SEQUENCE ............................................................................................................................................. 10
RWS SHIPPED INSIDE A TABLE FRAME .................................................................................................................... 10
TABLE TOP AND VACUUM SYSTEM ............................................................................................................................. 10
LIFTING / HANDLING THE EQUIPMENT...................................................................................................................... 10
FRAME ASSEMBLY....................................................................................................................................................... 11
TABLE TOP MOUNT AND ALIGNMENT ......................................................................................................................... 12
TABLE SECTION ALIGNMENT PINS ............................................................................................................................. 15
FRAME JUNCTION BRACKETS ..................................................................................................................................... 15
FINAL CHECK OF TABLE LEVELLING........................................................................................................................... 15
HORIZONTAL ALIGNMENT X-AXIS GUIDES............................................................................................................... 17
VERTICAL ALIGNMENT X-AXIS GUIDES .................................................................................................................... 18
ALIGN RACK JOINTS ................................................................................................................................................... 18
FRAME AND VACUUM SYSTEM.................................................................................................................................... 19
MOUNT TRAVERSE ONTO TABLE ................................................................................................................................ 21
INSTALL TABLE FRONT / REAR COVERS .................................................................................................................... 23
INSTALL THE CABLE CHAIN BRACKET ...................................................................................................................... 23
REVOLVING WORK STATION ...................................................................................................................................... 23
MOUNT MPU .............................................................................................................................................................. 23
MEASURING STATION ................................................................................................................................................ 23
CONNECT ALL CABLES ............................................................................................................................................... 24
CONNECT PNEUMATIC HOSE...................................................................................................................................... 24
FIXED CONNECTORS .................................................................................................................................................. 24
MAINS POWER CONNECTION ..................................................................................................................................... 24
MOUNT PC/KEYBOARD .............................................................................................................................................. 25
SYSTEM POWER UP .................................................................................................................................................... 25
CHECK FOR PROPER TABLE TOP JOINT...................................................................................................................... 25
MOUNT RACK COVERS ............................................................................................................................................... 25
MOUNT X1 / X2 COVERS, TABLE COVERS............................................................................................................... 25
MAP TABLE TOP .......................................................................................................................................................... 25
INSTALL OPTIONAL EQUIPMENT ................................................................................................................................ 26
ADJUST PHOTO CELLS ................................................................................................................................................ 26
INSTALL FRAME COVERS ............................................................................................................................................ 27
CLEAN UP INSTALLATION ........................................................................................................................................... 27
MARK THE WARNING AREA ON THE FLOOR............................................................................................................... 27
OIL AND GREASE CHECK FOR CORRECT LUBRICATION ........................................................................................ 28
CHECK / ADJUST ONE TOOL ...................................................................................................................................... 28
TEST RUN IAT ........................................................................................................................................................ 28
CUSTOMER TRAINING ................................................................................................................................................ 28
SUPERVISE AND HELP THE CUSTOMER THROUGH THE FIRST HOURS ..................................................................... 28
HSMU/HPMU INSTALLATION, GENERAL ISSUES ................................................................................... 29

2.1
ASSEMBLY DRAWINGS ............................................................................................................................................... 29

3
2.2
2.3
2.4
3.
ROUTER SETUP ........................................................................................................................................................... 29

HSMU/HPMU GALLOWS INSTALLATION ................................................................................................................. 30
GALLOWS HINGES INSTALLATION AND ADJUSTMENT .............................................................................................. 32
HSMU ISSUES .............................................................................................................................................................. 36

3.1
3.2
4.
HSMU SUCTION TUBE ASSEMBLY ............................................................................................................................ 36

ELECTRICAL BLOCKED SCHEMATIC ........................................................................................................................... 36
HPMU ISSUES .............................................................................................................................................................. 37

4.1
HPMU SUCTION TUBE ASSEMBLY ............................................................................................................................. 37
4.2
HPMU, ELECTRICAL BLOCKED SCHEMATIC.............................................................................................................. 38
4.3
CHILLER (OPTIONAL)................................................................................................................................................. 38
4.3.1 Chiller without heater ..................................................................................................................................... 38
4.3.2 Chiller, re-configuration to run properly at 15 oC / 59 oF. ............................................................... 38
4.4
CHILLER ASSEMBLY .................................................................................................................................................... 40
4.5
CHILLER, WATER TUBE ASSEMBLY ............................................................................................................................ 41
4.5.1 Chiller without heater ..................................................................................................................................... 41
4.5.2 Chiller including heater .................................................................................................................................. 41
4.6
CHILLER, ADAPT WATER TUBE LENGTH .................................................................................................................... 42
4.7
CHILLER, FILL COOLING WATER ................................................................................................................................ 42
4.8
CHILLER, BLEEDING THE PUMP ................................................................................................................................. 44
4.9
CHILLER, FLOW MEASUREMENT ................................................................................................................................ 45
4.10 CHILLER, CHECK FOR LEAKAGE ................................................................................................................................. 45
5.
VACUUM PUMP INSTALLATION ........................................................................................................................ 46

5.1
VACUUM PUMP AND TUBE ASSEMBLY ........................................................................................................................ 46
5.2
VACUUM PUMP, ELECTRICAL CONNECTIONS ............................................................................................................ 46
5.3
PUMP CONNECTIONS, SB200/SB310/SB430..................................................................................................... 47
5.4
PUMP CONNECTIONS, SB530/SB710 ................................................................................................................... 47
5.5
SOUND SUPPRESSOR FOR SB200/SB310/SB430 .............................................................................................. 47
5.6
SOUND SUPPRESSOR FOR SB530/SB710............................................................................................................. 48
5.7
SOUND SUPPRESSION CABINET FOR SB200/SB310/SB430 ............................................................................. 48
5.8
SOUND SUPPRESSION CABINET FOR SB530/SB710 ............................................................................................ 48
5.9
SOUND SUPPRESSION CABINET, INSTALLATION SEQUENCE ................................................................................... 49
5.10 E-SAVE VACUUM PUMP CONTROL .............................................................................................................................. 50
5.10.1 Introduction ................................................................................................................................................... 50
5.10.2 Installation ..................................................................................................................................................... 50
6.
REVOLVING WORK STATION ............................................................................................................................. 51

6.1
6.2
6.3
REVOLVING WORK STATION ...................................................................................................................................... 51

REVOLVING WORK STATION, ALTERNATIVE POSITION ............................................................................................ 52
ASSEMBLY................................................................................................................................................................... 53
7.
EXTENSION TABLE ................................................................................................................................................... 57
8.
CONVEYOR BELT ........................................................................................................................................................ 57

8.1
8.2
8.3
9.
CONVEYOR BELT MECHANICS .................................................................................................................................... 57

BELT TENSION ............................................................................................................................................................ 57
BELT GLUE PROCEDURE ............................................................................................................................................. 58
ROLL FEEDER INSTALLATION ............................................................................................................................ 63
10.
AIR COMPRESSOR ................................................................................................................................................ 64
11.
VACUUM CLEANER, ZEFIRO 75, FOR HSMU / HPMU ........................................................................ 64
11.1
12.
DIFFUSER ON AIR OUTPUT ........................................................................................................................................ 65
XP-GUIDE INSTALLATION ............................................................................................................................... 66
12.1
12.2
12.3
INSTALLING XP-GUIDE, PROCEDURE....................................................................................................................... 66

SETTING THE COM PORT .......................................................................................................................................... 70
LOADING NEW SW INTO THE CU-MODULES ........................................................................................................... 70
4
12.4
13.
INSTALLATION ON 32/64 BIT PC ............................................................................................................... 72
13.1
13.2
13.3
14.
BACKUP....................................................................................................................................................................... 71
XP-GUIDE .................................................................................................................................................................. 72
TDVIMAGE .................................................................................................................................................................. 72
ARS CAMERA DRIVER ................................................................................................................................................ 72
ARS SOFTWARE INSTALLATION .................................................................................................................. 73
14.1 OBTAIN THE SCORPION SOFTWARE LICENSE........................................................................................................... 73

14.2 MAC - ADDRESS ......................................................................................................................................................... 73
14.3 INSTALL XL-GUIDE ................................................................................................................................................... 74
14.4 TDVIMAGEX INSTALLATION ...................................................................................................................................... 74
14.4.1 Windows 7 installation ........................................................................................................................... 74
14.5 INSTALL FIREWIRE CARD AND CAMERA .................................................................................................................... 76
14.5.1 Install driver for the FireWire camera. ................................................................................................ 76
14.6 UPDATE DEVICE DRIVER ............................................................................................................................................ 80
14.7 CONFIGURE CAMERA FOR ARS ................................................................................................................................. 84
14.8 UPDATE THE ARS LICENSE ....................................................................................................................................... 86
14.9 INSTALLING CAD-X, PROCEDURE............................................................................................................................ 87
15.
I-CUT INSTALLATION ........................................................................................................................................ 89
15.1
15.2
15.3
15.4
15.5
15.6
16.
INSTALL XL-GUIDE ................................................................................................................................................... 89

INSTALL I-CUT HARDWARE AND SOFTWARE ............................................................................................................ 89
CONFIGURE I-CUT FOR KONGSBERG XN WITH I-CUT ............................................................................................ 89
HOW TO UPDATE THE I-CUT LICENSE CODES .......................................................................................................... 90
I-CUT PRODUCTION SETTINGS FOR KONGSBERG .................................................................................................... 91
HOW TO CHECK CAMERA OPERATION ....................................................................................................................... 92
DOCUMENTATION................................................................................................................................................. 93
1. Table installation
1.1 Introduction
This document provides a brief guide about how to install the Kongsberg XP tables.
It is aimed especially for Eskoservice personnel.
It is a prerequisite that the service personnel installing the machine are properly trained and have a
good knowledge about the system.
In addition to this procedure, the following documents contains information regarding the XP
system:
Title
Purpose
How to get started
Short form introduction
Site Preparation
Instruction manual
How to prepare for installation
User Manual
User manual
Online Help
Context sensitive help
Technical reference
Technical information for special purpose
Test manual
How to run HWT900xp test programs
Technical manual
Technical information aimed for service needs
Training plan
A plan for customer training
Maintenance manual
Detailed description of XP maintenance requirements
XP spare part
Spare parts for XP, register and images
XP consumables
List of consumables
1.2 Special tools

An overview describing the most important tools necessary for installation and maintenance of XP is
available in the Maintenance manual for XP.
1.3 Table installation sequence

This is an overview showing the recommended installation sequence. In the next chapter, you will
find a detailed description on each item:
Inspect the equipment
Inspect the customers preparation
Decide where in the room to locate the system
Verify acceptable floor level / flatness
Move the crates into the room
Unpack the equipment
Install table and traverse
Connect all cables
Mains power connection. System power up
10
Oil and grease check for correct lubrication
11
Setup and adjustments
12
Test run - IAT
13
Customer training
14
Supervise and help the customer through the first hours with the new system
1.4 Inspect the equipment

If a crate is damaged after transit, it must be left exactly as it is and the damage reported as
follows:
When to report
Report to
Transport company:
Always
Make a remark on the transport document to

that effect.
If Esko was responsible for shipping.
Local Esko office or representative.
If the customer was responsible for

the shipping.
Customer's insurance company.
In either case, nothing further should be done with the item until the representative of the insurance
company has inspected the damage and decided what action is to be taken.
1.5 Inspect the customers site preparation

In the Site Preparation Manual, all requirements for the system are listed regarding
Mains supply
Pressurized air supply
Verify proper installation of:
Vacuum pump wiring, power and vacuum tubes.

Pressurized air supplies and air outlet.
Mains power single phase for MPU. Wall outlet.
Mains power for other external equipment, as PC, Sheet Feeder ++.
1.6 Requirements for acceptance test

Clarify if there was a benchmark or other expectations to be met by the acceptance test of the
installed system. Ensure together with the customer that proper material is available.
1.7 Decide where in the room to locate the system

In the Site Preparation Manual, a footprint showing the different installation alternatives for the XP
models is shown.
Use that information to decide where in the room to install the system. Mark on the floor the
position of the cutting table frame legs.
1.8 Decide space for temporary storage

Clarify together with the customer where to unpack the boxes.
Clarify temporary storage for packing materials etc.
1.9 Verify acceptable floor level

The floor prepared for the machine should meet the following requirements:
It should be level.
The flatness should be within +/- 5 mm (+/- 0.2).
1.10 Move the crates into the room

If possible, keep the equipment inside the crates until the crates are moved to the desired spot.
The system is shipped in a number of crates.
In the Site Preparation Manual, the weight and dimensions of the crates is specified.
1.11 Unpack equipment

Before unpacking, move the crate to a position where it is suitable in order to easily bring the
equipment to its final destination.
Take into account:
Minimize the distance you have to move the equipment.
Note the box orientation; avoid turning the equipment after unpacking.
Keep all transport latches in place as long as the equipment is moved.
1.12 Box orientation

Table top and frame boxes are marked as follows:
1.13 Unpacking sequence

The unpacking sequence highly depends upon the destination location.
A recommended sequence could be:
1. Unpack frame for table section 2 (frame 2).
2. Move frame 2 close to its final destination.
3. Unpack table top 2.
4. Mount and preliminary fix table top 2 on top of frame 2. About vacuum system mount, see
next chapter
5. Unpack frame 1.
6. Move frame 1 close to its final destination.
7. Unpack table top 1.
8. Mount and preliminary fix table top 1 on top of frame 1.
1.14 RWS shipped inside a table frame

If RWS is shipped inside the table frame, unpack in this sequence:
Remove the top and walls of the shipping box.
Lift the frame straight up and out.
Now the rest of the shipment is easy available.
1.15 Table top and vacuum system

During the process of moving the vacuum table
onto the frame, remove the vacuum tubes
entering the vacuum table (marked with red).
1.16 Lifting / handling the equipment

Due to heavy weight, care should be taken when lifting / handling mechanical pieces. In the Site
Preparation Manual, you will find a detailed description about how this can be done in a safe way.
10
1.17 Frame assembly

On the base frames, mount the foot screws
together with the locking nuts.
When mounting the screws, leave an
adjustment space as indicated at left. This
should allow for height adjustment of the
cutting table.
Place the frames on the footplates in the
position decided.
There should be washers beween the table

frame and the table top.
If suitable, mounting the washers can be
done afterwards.
Or put flat washers between the table base
and the tabletop.
Lift the table section on top of the frame.

Ensure the washer is in place.
Insert the alignment pins (in two corners).
Fix the table top to the frame.
11
1.18 Table top mount and alignment

Position the base frame for table
section 1 in a correct position
relative to walls etc.
Place table section 1 on top of the
base frame.
Loosely mount the table fixing
screws.
Use a waterpass on top of the
table surface and adjust the foot
screws until the tabletop is level
in both directions.
As the X-axis guides and racks
extends from the table body, we
have to be very careful when
handling the table section.
Place table section 2 on top of the
base frame.
Loosely mount the table fixing
screws.
Carefully slide table section 2

towards section one.
Stop in the position indicated at
left.
Adjust the height of table 2 to fit
with table 1.
Use a waterpass on top of table 2
and adjust until the tabletop is
level in both directions.
Carefully slide table 2 towards

section 1.
12
Use a high-quality water pass to
ensure correct levelling.
Using a tension belt as shown at

left on each side is recommended.
By this, you can move the table
slowly and controlled into correct
position.
Check the distance between each frame using measures from the figures on the next pages (all
numbers in mm).
Check these values:
Metric (mm)
Inches
1341
52.8
1927
75.9
3099
122
3685
145.1
13
XP24/44
14
1.19 Table section alignment pins
Insert alignment pins.
1.20 Frame junction brackets
Frame junction brackets - observe the marking
1.21 Final check of table levelling

Use a waterpass on top of table 2
and check that the tabletop is
level in both directions.
Check that the table height of
section 2 fits section 1.
15
Ensure all frame foot screws have
proper contact to the floor. Tighten
up all foot screws.
Be careful not to turn the screws

and thus lift the frame leg.
16
1.22 Horizontal alignment X-axis guides

For this purpose, use the Guide
Adjustment tool prepared for XP.
One example:
You have to add shim in order to make
the guides meet perfectly.
The illustration is a top view showing
the joint between two X table sections
(X-guides).
Loosen one or more fixing screws on

the guide you are about to move.
Now, by adjusting the screw on the

adjustment tool, you force the guide
outwards, allowing insertion of shims.
The above procedure completes the horisontal adjustment of the guides.

In addition, you have to ensure vertical alignment of the two guides before the guides are fixed.
17
1.23 Vertical alignment X-axis guides

Use a steel pin (router bit) and move it along
the top of the guide.
When passing the joint between two guides,
ensure smooth movement (no resistance).
1.24 Align rack joints

For this purpose, mount a Dial Gauge
Puppitast on the Guide Adjustment tool
prepared for XP as shown.
To be able to measure
the height of the rack,
place a steel pin,
2mm, inside one and
one tooth.
In order to keep the
pin in place, it should
be magnetized using a
small permanent
magnet.
Just rub the pin against the magnet
before use.
18
Measure and adjust the height of the rack
on both sides of the joint until they are
even.
Fix the racks in this position.
Measure the height of the rack when the

measuring pin is in the joint.
All three heights measured should be
exactly equal in order to avoid mechanical
noise when the traverse is passing the
joint.
In order to achieve the optimal

adjustment of the rack height in the joint,
it might be necessary to loosen the foot
screws and carefully adjust the table top
level.
This procedure must be carried out for

both sides of the table.
Tighten up all foot screws and lock using
the locking nuts.
The rack adjustment is completed.
1.25 Frame and vacuum system

Complete vacuum system installation beneath the table top
19
The vacuum system shipped partly mounted
inside the frame.
This illustration shows the vacuum system in

correct position.
To enter the vacuum tubes into the vacuum
table, the vacuum system has to be lowered.
Use a set of tension belts to keep the vacuum

system up during table top mount.
Mount the vacuum tubes.
Carefully enter one and one vacuum tube into

the vacuum table.
Use the tension belt to keep the vacuum
system up during this process.
20
When in position, fix the vacuum system to the
frame.
1.26 Mount traverse onto table
Clean the racks and guides on the table before the traverse is mounted onto the table.
On the cutting table, remove the plus X end
stoppers.
The traverse should be entered from the plus X
side.
21
On the traverse, apply grease to the runner
blocks before the mounting tool rails are
mounted.
Ensure the mounting tool rails are inserted into
the runner blocks. These mounting tools should
be pushed out from the runner block as the
traverse is mounted onto the table.
With at least one person on each end of the

traverse, carefully lift the traverse up and slide it
onto the X-axis guides.
Note: As you see from the illustration, the

distances from the X-axis runner blocks in X1 and
X2 and to the traverse beam are not equal.
To ensure that the traverse beam is entered
correctly, parallel to the table, you have to look at
the traverse beam itself.
Insert the +X end stoppers.

Ensure the X end stoppers are properly mounted
as well.
22
1.27 Install table front / rear covers
1.28 Install the Cable Chain Bracket

Prepare for the cable chain.
1.29 Revolving work station

The Revolving work station is shipped completely assembled, ready to be mounted.
If more details are needed, RWS is discussed in a later chapter.
1.30 Mount MPU

Mount and fix MPU cabinet.
Connect and assemble the cables in a nice way beneath the top frame.
1.31 Measuring station

Mount the measuring station as shown at
left and connect the cable.
1. The cover around the measuring

station must be levelled equal to the
top of the cutting table.
2. The top of the measuring pad should
be 2 mm (5/64 inch) above the
surrounding level.
23
To prevent from dust coming into the
encoder, protect it with some textile
adhesive tape.
Complete the Calibrate foot on the
measuring station wizard available
from:
Main Menu->Options->Table Option
1.32 Connect all cables

Connect all cables according to labels.
Mount the cable chain and fix it to the traverse.
Use cable ties where necessary to fix the cables properly. Avoid cables on the floor.
1.33 Connect pneumatic hose

Connect the pneumatic hose to the Pressurized air regulator.
Connect to wall outlet.
1.34 Fixed connectors

Ensure that all DSUBs are properly mounted and fixed.
Ensure the two screws are properly tightened.
Check:
MCU
RWS
Operator panel
Traverse end X1 and X2
Y-carriage
MPU, all inside connections
Inside frame, vacuum connectors++.
Ensure that other electrical connections are properly fixed and with tension releases.
1.35 Mains power connection

In the Technical manual, you will find electrical schematics showing how to connect and configure
for different mains voltages.
Before connection, ensure correct voltage level using a Volt meter.
24
1.36 Mount PC/keyboard

Assemble the cables in a nice way beneath
the top frame.
1.37 System power up

Power up the system:
Run the Hwtest program to verify that each motor is operating properly.
Run XP-Guide and complete the Table Zero Sequence.
1.38 Check for proper table top joint
By jog, move the traverse across table joints.

Passing the joint should be smooth, without any additional noise
If any unusual noise is heard, fine-tune the table joint adjustment.
1.39 Mount rack covers

1.40 Mount X1 / X2 covers, table covers
1.41 Map table top
Complete the Map Table top wizard.
Mapping the table top should be carried out directly on top of the vacuum table regardless if there
will be a conveyor belt mounted later on.
25
1.42 Install optional equipment

Install optional equipment:
Installation procedure, page
HSMU
(29)
HPMU gallows
(29)
HPMU chiller
(29)
Vacuum pump, sound suppressor
(46)
Extension table
(57)
Conveyor belt
(57)
Air compressor
(64)
Vacuum cleaner
(64)
1.43 Adjust photo cells

Adjust photo cell transmitter until the beam is
centered around the receiver input lens.
Check all photo cells.
Note:
The red square is visible if the surroundings are
dimmed.
26
1.44 Install frame covers

Correct cover position is marked by part number on
the frame.
Each cover has a part number label.
1.45 Clean up installation
Fix remaining loose cables properly.

Clean table surface.
1.46 Mark the warning area on the floor
Included in the shipment is a roll of yellow/black tape.

Use this tape to mark on the floor an area close to the cutting table where special attention should
be made.
The distances in the figure are proposals; you should adapt this marking to the local situation.
27
1.47 Oil and grease check for correct lubrication

In the Maintenance manual for Kongsberg XP, you will find a description of how to perform required
maintenance.
In the procedure, the following chapters should be completed as part of the installation.
Note: The machine is greased from the factory. Thus, what to do here is to check that everything is
ok.
X1, X2 AND Y RACKS, HOW TO CLEAN AND LUBRICATE
X1 AND X2 PINION, CLEANING AND LUBRICATION
Y PINION, CLEANING AND LUBRICATION
X1 AND X2 GEAR, CLEANING AND LUBRICATION
Y GEAR, CLEANING AND LUBRICATION
X1 AND X2 GEAR AND RUNNER BLOCKS, QUICK LUBRICATION
Y RUNNER BLOCKS, QUICK LUBRICATION
Z-AXIS TIMING BELT
Z-AXIS SCREW AND TIMING BELT
Z-AXIS GUIDES
1.48 Check / adjust one tool

Check / adjust one tool, in one position.
Check and adjust all other tools included together with the customer, as part of the training.
1.49 Test run IAT

Load material onto the table and complete some test runs.
A set of sample files is available from the c:\XP-guide\samples directory if not available from the
customer.
1.50 Customer training

Complete customer training.
1.51 Supervise and help the customer through the first hours
Stay available to the customer during his first hours with the new system.
28
2. HSMU/HPMU installation, general issues

2.1 Assembly drawings
HSMU on XP20 (407499)
HSMU on XP24 (407491)
HSMU on XP44 (407492)
HSMU inverter (405643)
The IBAG starter unit and the Inverter are

located inside the table frame.
2.2 Router setup

From the Options->Router Setup dialog, the
physical COM-port used for communication with the
Milling Unit (HSMU/HPMU) is specified.
Note
The inverter needs to be connected to a genuine COM
port.
If connected to a USB-to-COM adapter, the
communication will fail.
29
2.3 HSMU/HPMU gallows installation
The gallows is always located on the X2 side of the table on the same side as where the Revolving
work station is located.
30
Fix the gallows shaft to the table frame on the

X1 side
..and on the X2 side.
Here, we are ready to mount the gallows

frame. Normally, this frame is shipped partly
assembled.
Fix the gallows frame to the gallows shaft.
Mount the safety walls
31
HSMU/HPMU parking bracket
2.4 Gallows hinges installation and adjustment

Hinge tensioning has to be completed at installation time. Follow this procedure.
Note:
You should use gloves and safety glasses during this job.
The hinges are greased from the factory. If you are in

doubt, add 5 strokes of grease into each spring.
32
Top view
The hinges are mounted onto the vertical beam.

Mount the gallows to the hinges.
In this position, you are ready to tension the hinges.
Insert the tension lever into one of the holes in the

tension ring.
Apply tension so that the locking pins will always be
engaged.
33
Enter and fix the locking pin.
Repeat the procedure for the other tension spring
and fix the locking pin properly.
34
Now, the gallows should be ready for operation.
Put the tension lever in the tool kit for future use.
35
3. HSMU issues
3.1 HSMU suction tube assembly
Anti-static tube connection

It is important that the tube assembly is made anti-static.
All parts described has conductive power, in addition, it is important to secure electrical contact in
every joint.
3.2 Electrical blocked schematic

Note: A more detailed description is
available in the Technical manual for XP.
36
4. HPMU issues
4.1 HPMU suction tube assembly
Anti-static tube connection

It is important that the tube assembly is made anti-static.
All parts described have conductive power; in addition, it is important to secure electrical contact in
every joint.
37
4.2 HPMU, electrical blocked schematic
Note: A more detailed description is available in the Technical manual for XN.
4.3 Chiller (optional)

4.3.1 Chiller without heater
A solution allowing the chiller to run without heater was introduced in February 2013. A prerequisite
for this solution is:
1) that the cooling water is kept above 15 oC / 59 oF (within limits as described in the Site
preparation manual.
2) that the chiller is programmed to run properly at that temperature.
4.3.2 Chiller, re-configuration to run properly at 15 oC / 59 oF.

Warning
If possible, do the reconfiguring with water in the tank.
If reconfiguring is done without water in the tank, let the chiller be switched on for 2-3 minutes
maximum.
38
1) Entering Parameter setting mode: Keep the "SET"-Button
pushed until "PS" appears on the screen.
2) Press "SET" again (short), "0" will appear on the screen.
3) Enter password (22): Change the value with the arrowup-button to "22".
4) Press "SET" (short).
5) Select the "Alarm"-parameter: Press the arrow-upbutton until "AL" appears on the display.
6) Press "SET" (short), "6" should appear on the display.
"6" is the old value, already programmed. It is the
alarm-temperature relative to the set-temperature (25
[C] - 6 [K] = 19 [C])
7) Change that value to "10" by using the arrow-keys. New
value (25 [C] - 10 [K] = 15 [C])
8) Press "SET" shortly.
9) Keep "SET" pressed until the temperature-display
appears again (important step, otherwise the changes
wil not be saved permanently).
To confirm correct setting, repeat the procedure
without saving.
Enter the label
42457523 LABEL 15 Celsius 59 Farenheit
as shown.
This label indicates that the chiller is configured for 15 oC /
59 oF.
Chiller 230V
Chiller 115V
39
4.4 Chiller assembly

Chiller for 230V mains supply:
Chiller unit prepared for 230V.
Heater unit (230V).
Water tube assembly is indicated.
Chiller for 115V mains supply:
Chiller unit prepared for 115V.
Heater unit (230V).
Transformer 115->230V for heater
40
4.5 Chiller, water tube assembly

4.5.1 Chiller without heater
4.5.2 Chiller including heater
Prepare the tube going from heater to chiller in this way:
41
1) Tube from Chiller to HPMU as shipped from

factory
2) Cut the tube as shown.
The cut should be straight and clean.
3) Connect the tubes as shown in the
illustration.
4.6 Chiller, adapt water tube length

The water tubes are delivered at a standard length.
If the water tubes are too long for the actual installation, they should be cut to proper length.
That is easy done with a sharp knife.
Note: It is important the cut is straight and clean.
4.7 Chiller, fill cooling water

When shipped from factory, the chiller is empty; no cooling water is inside.
Therefore, the chiller water tank has to be filled and chiller water tubes connected before any
spindle operation.
Procedure:
The chiller water tubes and chiller control cables/mains cables are connected.
Dis-connect the chiller heater unit from mains.
42
Fill the chiller water tank with fresh water, approximately
17 liters.
It is possible to fill the tank through the tube inlet on top

of the chiller or you can remove chiller cover and fill
directly into the water tank.
Observe water level on the water level tube.
Add cooling liquid 1:10 (17 liters of water 1.7 liters of

cooling liquid).
Now you are ready to power up the chiller; start the pump.
As the first task, complete the Chiller, bleeding the pump chapter available on the next page.
Run the chiller for at least two minutes to ensure the cooling system is filled with water.
Connect the chiller heater unit to mains.
Now you are ready to run.
43
4.8 Chiller, bleeding the pump

This procedure should be completed as the first task after the chiller water tank has been empty and
filled (again) with fresh water:
Pre-requisites:
The chiller is not running.
Power to the chiller heater unit is dis-connected.
The water tank is filled with water (and cooling liquid).
On the chiller water outlet connector, remove the water

tube from the connector.
Some air will be forced out from the system before it is

filled with water.
Observe water flow out of the outlet connector.
Insert the water tube into the outlet connector again.

You are ready to continue.
44
4.9 Chiller, flow measurement

During operation, check the water
flow level displayed on the chiller
meter.
For proper operation, the flow level
should be > 1,0 l/min.
4.10 Chiller, check for leakage

As the last action, examine the water cooling system carefully for leakage.
Take a look at each joint, and ensure there is no leakage.
45
5. Vacuum pump installation

5.1 Vacuum pump and tube assembly
Please consider this when installing the vacuum pump:

1. The vacuum pump is noisy. If possible, install it in an area where people are not disturbed.
2. The pump gets warm. Do not install the pump below the cutting table.
3. The air output is warm. Avoid air blow towards electronic equipment of any kind.
4. Avoid warm air blow in beneath the cutting table.
5.2 Vacuum pump, electrical connections
For electrical schematics, see Technical manual.
46
5.3 Pump connections, SB200/SB310/SB430
5.4 Pump connections, SB530/SB710
5.5 Sound suppressor for SB200/SB310/SB430
47
5.6 Sound suppressor for SB530/SB710
5.7 Sound suppression cabinet for SB200/SB310/SB430
5.8 Sound suppression cabinet for SB530/SB710
48
5.9 Sound suppression cabinet, installation sequence
Place the vacuum pump in the wanted position.
Insert the foot screws.
Mount Sound suppression unit 2.
Mount the pump connection tubes.
Place the cabinet insert beneath the vacuum

tubes as shown.
Adjust the foot screws until the tubes gets

straight out from the pump.
Fix the foot screws in this position.
Connect the electrical cables.
The motor cable goes through the plug in the

cabinet insert.
For electrical schematics, see Technical manual.
Place a support brick (wood or similar) as shown

at left.
Turn the sound suppression cabinet until it rest on

the brick.
Adjust the position of the cabinet insert and the

cabinet itself until it fits.
Remove the brick
The sound suppression cabinet should now be

correctly positioned onto the insert.
Fix the cabinet insert.
49
5.10 E-save vacuum pump control

5.10.1
Introduction
Vacuum pump controlled by a variable frequency
drive (VFD) is available as an option using Vacon
inverter.
A closed loop is provided by a vacuum sensor located
close to the vacuum pump.
5.10.2
Installation
The inverter should be mounted on the wall, close to the vacuum pump.
The inverter is ready to run as soon as the mains power is switched on.
Note:
1) The inverter is generating noise, thus it is recommended to mount the inverter together with
the vacuum pump in a separate room.
2) Ensure proper installation:
More information is available in the Technical manual for XP.
50
6. Revolving work station
6.1 Revolving work station

The work station top can be rotated 90o.
51
6.2 Revolving work station, alternative position

Two alternative positions for the Revolving work station are prepared, configurable at installation
time:
This is the Standard Revolving work station
position.
This is the alternative Revolving work station

position.
The Standard Revolving work station position is

recommended when HSMU/HPMU is installed.
52
6.3 Assembly
The Revolving work station will be partly assembled when shipped from Kongsberg.
Use what you need from this procedure:
If not available, drill the fixture holes in the
frame beam.
Fix the Revolving work station to the frame.
Fixture hole information:

L = 120 mm / 4.72 inches.
W = 258 mm / 10.16 inches.
D = 2 x 9.0 mm / 0.35 inches.
How to arrange cables?
Slightly loosen the two screws

A
Loosen the two screws B
Remove the bracket.

Arrange all cables nicely into the
slot.
53
Mount the bracket again.
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.
Fix the top frame to the top disk.

Mount all cables for MCU, switches, screen,
keyboard and mouse nicely from the column
and up.
54
Internal cabling.
Mount the plastic cover and fix it to the top
frame.
DELL PC fixture
1 Fixing screw
2 Bracket balancing screw. Adjust the
screw until the bracket is horizontal. Then fix
the bracket using the fixing screw
HP PC fixture:
Drill a 7mm / 0.3 in. hole in screen foot
HP PC fixture:
Use one of the available fixtures on RWS.
55
Assemble the cables in a nice way beneath
the top frame.
56
7. Extension table
Included in the shipment is an assembly drawing.
8. Conveyor belt
8.1 Conveyor belt mechanics
8.2 Belt tension
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 path.
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.
57
8.3 Belt glue procedure

The cut angle and distances are found in this figure 1:
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
58
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.
59
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.
60
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.
61
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.
Put a hard, flat material on top of the belt

splice.
Add some heavy weight.
62
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.
9. Roll feeder installation
63
Total machine length is extended by 600
mm / 24 in. plus space for roll handling.
10. Air compressor

Installation to avoid that compressed air accidentally being switched on while maintenance is carried
out:
1. An outlet for compressed air connection should be located in a position where it is visible
from the equipment.
2. Alternatively, a lockable compressed air ON/OFF switch can be installed.
All installations should be according to local regulations.
11. Vacuum cleaner, Zefiro 75, for HSMU / HPMU

Dimensions:
620 x 800 mm, height 1650 mm / 24.4 x 31.5 in, height 65 in.
64
11.1 Diffuser on air output

Included in the shipment is an air diffuser, ready to
be mounted onto the suction unit output.
65
12. XP-Guide installation

12.1 Installing XP-Guide, procedure
XP-Guide is prepared for Windows XP / W7 PCs.
Make sure Windows XP/W7 is already installed and running on your computer.
For the control system to work properly, it is a requirement that the operator has Administrator
privileges setup on the Front End PC; when starting the program, select Run as administrator
from the right mouse button menu.
Notes
The GUI is by default installed in the c:\XP-Guide directory
For temporary file storage, the XP-Guide program will use the temp-directory for the actual user.
The minimum space required depends upon the size of the Input Files executed. The space
should be at least twice the size of the largest Input Files.
From the XP-Guide CD, run the installation as follows:
Double-click setup.exe.
Click Next
66
If a local language is wanted, select
from the list and click Next.
Click Next.
The installation begins.
Your PC is now upgraded with the
required software.
Different windows might appear,
depending upon the status of your
PC.
Click Next.
67
Select Repair.
Select Install.
Select Finish.
68
Answer Yes if the CUmodules
should be updated.
The application program Sysload will
be executed.
For detailed information about
loading software into CU-modules,
see separate chapter.
Click Finish.
Re-boot your PC if that is asked for.
69
12.2 Setting the COM port

If this is a first time installation, a proper setting of the COM port for communication between the
Front End PC and the GC800 controller might be necessary.
This is done from the program SysLoad included in the XP-Guide sw.
After XP-Guide installation, Sysload is available as a desktop icon:
1. Switch the machine off and on again.
2. From the desktop, select the program
SysLoad.
3. Answer No to the question if all CUmodules should be loaded.
4. Select the Options dialogue
5. Set correct communication port (the
serial port where the serial line to the
cutting machine is connected).
6. Select OK.
7. Exit from the SysLoad program.
12.3 Loading new SW into the CU-modules

Loading new software into the CU-modules is carried out as part of the installation program, as
described in previous chapter.
It is possible to load software into the modules as a separate operation:
Loading software into CU-modules is carried out using the SysLoad program.
Please follow the this procedure:
1. From the Windows Start menu or from
desktop, select the program SysLoad.
2. You will be asked if all modules should
be loaded. In normal cases, answer
Yes.
70
3. The program checks current
installation and files to be loaded.
4. Start load by choosing the Load
button in the information dialogue.
Loading of software will be carried out for
the CU-modules in sequence.
If you are about to update only one or two
CU-modules with new software, using the
Update function will save you some time.
If the Program Load dialog shows that all
CU-modules are updated, as you see in
the picture at left, no update of CUmodules is necessary.
5. When load finished, the new state of

the system is displayed.
6. Exit from SysLoad.
12.4 Backup
Please keep the original CD ('s) in a safe place once the installation is completed. It is highly
recommended that you make a backup copy of the following data files on a regular basis:
c:\XP-Guide\system\ttop.dat
c:\XP-Guide\system\gc900xp.ini
c:\XP-Guide\system\diffX2X1v2.dat
c:\XP-Guide\system\diffX2X1v2.txt
c:\XL-Guide\system\Timecounter.ini
c:\XL-Guide\system\TimeCounter.tc
c:\XL-Guide\system\TimeCnt.log
c:\XL-Guide\system\XLTools.xml
These files store all adjustments and system settings and are thus critical for correct system
operation.
Additionally, it is highly recommended you make a backup copy of all Job Setup files, which are
located in the directory, c:\XL-Guide\setup. These files store all cutting information for the various
materials used.
Backup should be made regularly and each time after changing or adjusting mechanics, tools, Job
Setup etc.
71
13. Installation on 32/64 bit PC

13.1 XP-Guide
XP-Guide will install and run properly on both 32 and 64 bit PC.
13.2 TdvImage
Separate 32/64 bit versions of TDVImage.spb files are included in the shipment.
The installation program will install correct version.
13.3 ARS camera driver

Separate 32/64 bit drivers are prepared for the Unibrain camera used for ARS.
Drivers are available on the XP-Guide CD folder: Drivers\unibrain.
For 32 bit: FireiSetupX86_120408.exe
For 64 bit: ubCorePro64_033109.exe
72
14. ARS software installation

Scorpion software has to be properly installed before any of the automatic ARS functions can
operate.
Installing the ARS software should be carried out in this sequence:
14.1 Obtain the Scorpion software license

For the Scorpion software to run properly, you need a license from the supplier.
In order to receive the license, you need the mac - address for the pc where the program is
installed.
This mac - address is returned to Esko Kongsberg, who will generate a new license code and return
it to the customer.
14.2 mac - address

To obtain the mac - address, proceed as follows:
1) On the PC, select Start->All Programs->Accessories->Command prompt ( to enter DOS
mode ).
2) Key the command: ipconfig /all
3) The following printout should appear on the screen:
Windows IP Configuration
Host Name . . . . . . . . . . . . .: 678h80j
Primary Dns Suffix . . . . . . . .: xxxx.com
Node Type . . . . . . . . . . . : Hybrid
IP Routing Enabled. . . . . . . . : No
WINS Proxy Enabled. . . . . . . : No
DNS Suffix Search List. . . . . . : xxxx.com
Ethernet adapter Local Area Connection 5:
Connection-specific DNS Suffix . : xxxx.com
Description . . . . . . . . . . . : 3Com 3C905B-COMBO Fast Ethernet Adapter (Generic)
Physical Address. . . . . . . . . : 00-01-02-2F-51-B8
Dhcp Enabled. . . . . . . . . . . : Yes
Autoconfiguration Enabled . . . . : Yes
IP Address. . . . . . . . . . . . : 10.31.176.66
Subnet Mask . . . . . . . . . . . : 255.255.255.0
Default Gateway . . . . . . . . . : 10.31.176.1
DHCP Server . . . . . . . . . . . : 10.31.128.40
DNS Servers . . . . . . . . . . . : 10.31.128.40 10.31.128.41
Primary WINS Server . . . . . . . : 10.31.128.40
Secondary WINS Server . . . . . . : 10.31.128.41
Lease Obtained. . . . . . . . . . : 15. oktober 2004 10:10:44
73
Lease Expires . . . . . . . . . . : 23. oktober 2004 10:10:44
4) The mac address is the number following 'Physical Address' in the printout (00-01-02-2F-51-B8).
5) Send this number to Esko Kongsberg, by phone or mail, and receive the license code in return.
6) Enter the command: Exit to return to Windows.
14.3 Install XL-Guide

Insert the XL-Guide CD in the CD drive and complete XL-Guide installation. Leave all choices to
default.
14.4 TdvImageX Installation

To install TdvImage, run setup.exe from the Tdvimage folder on the XL-Guide installation CD.
14.4.1
Windows 7 installation
In some occasions, we have experienced trouble when installing TdvImageX on a Windows 7 PC.
Typically, you get this error message when the Xx-Guide is started:
In order to install correctly, the User Account Control setting must be set to its lowest level before
TdvImageX is installed:
74
75
User Account Setting is available from the Desktop: Start->Control Panel.
In the Search Control Panel field, enter the letters uac.
The User Account Settings dialog appears.
14.5 Install Firewire card and camera

Turn computer off and install the FireWire card in a PCI slot.
Connect the camera.
Start the computer.
Windows recognizes it as a Generic 1394 Desktop Camera and installs the driver for it.
In order for ARS to work, the generic driver has to be replaced with Unibrain Fire-I driver as follows:
14.5.1
Install driver for the FireWire camera.
First, the driver files must be installed on the PC hard disk:

On the XL-Guide CD, browse to: Drivers\Unibrain
Double-click the file: FireiSetupX86_120408.exe (32bit) or ubCorePro64_033109.exe (64bit).
76
Click Next to start installation:
Click Yes.
77
Enter information and click Next.
Click Next.
78
Click Next.
Click Finish
You may now replace the generic camera driver that Windows XP installs automatically, with the
correct Fire-I driver as follows:
79
14.6 Update device driver

Open the Properties for My Computer (Start -> right click My Computer and select
Properties). Open the Hardware tab.
Click Device Manager button.
Expand the Imaging Devices category

Right Click the Generic 1394 camera and select Update driver
80
Select Install from a list or specific location and click Next.
Select Dont search. I will. and click Next.
81
Click Have disk:
Browse to c:\Program Files\Unibrain\Fire-i\Drivers. Click Open, then OK:
82
Select the Unibrain Fire-I driver and click Next:
Click Continue Anyway
Click Finish to complete the wizard.

The Camera driver installation is complete.
83
14.7 Configure camera for ARS

Go to Options -> Camera Config -> Camera tab. Double-click the line shown in the Camera Settings
section:
It brings up another Camera Setting window:
Click the dotted button to the right of the Camera line.
84
Select the Unibrain Fire-I camera and click OK to specify:
Click OK back through the

windows/dialogues until you are back in
the Camera Config window.
Observe that you can take a snapshot or
show live video in the Image tab, when
you click the corresponding buttons.
Leave the Live Video button active.
Close the window.
85
14.8 Update the ARS license

Follow this procedure to update the ARS license:
In XL-Guide, open the registration setup dialog:
XL-Guide->Options->Camera setup:
1. Select ARS license available.
2. Close the dialog
3. Close XL-Guide.
4. Restart XL-Guide.
5. Open the registration setup dialog:
XL-Guide->Options->Camera setup.
6. Select Camera setup
In the Camera setup dialog, select the Misc

tab:
1. In the License field, press the Change
button.
2. Enter (paste) the license code obtained in
chapter 5.1 5.2 (73).
3. Exit from the dialog.
4. License is upgraded.
The camera and system is now configured and ready to be used with ARS.
In the User manual for XN, you will find the following ARS relevant chapters:
Camera calibration
Camera offset adjustment
Verify correct offset adjustment
ARS modes of operation

Work with ARS
Create pre-defined register marks using ArtiosCad.
86
14.9 Installing CAD-X, procedure

CAD-X is a software module that makes it possible for other programs, such as XP-Guide, to use
functions from within ArtiosCAD.
It is a pre-requisite for a proper CAD-X installation that ArtiosCAD is installed on the PC before the
installation begins.
On the XP-Guide CD, go to the sub-folder Cadxcontain.
Double-click setup.exe.
Click Next
Click Install
87
Click Finish
88
15. i-cut installation

15.1 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 XN Installation Manual.
15.2 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.
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 Users manual.
15.3 Configure i-cut for Kongsberg XN with i-cut

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:
89
From the Plotter Type drop down menu, select the proper Kongsberg table. More information
about system setup is available in i-cut Users manual.
15.4 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.
90
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.
15.5 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
91
15.6 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.
Two adjustments are available:
A - Adjust the aperture.
F - Adjust camera focus.
92
16. Documentation
A Documentation DVD is included in the shipment.
Follow instructions on the label and install documentation on the Front End PC.
93

3090InstallationMan XP

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Installation Manual

A Publication of: Esko

Document number: D3090

P.O.Box 1016, N-3601 Kongsberg, Norway

Expak tool for clips added

Router serial line setup added

HSMU/HPMU gallows suction tube assembly modified

Vacuum tubing chapter has been updated

HPMU el. schematics updated

HPMU chiller without heater introduced.

Emphasize the importance of fixed connectors.

HPMU gallows tension adjustment added

Installation on 32/64 bit PC, chapter added

Document is adapted to the Standard Work Flow.

TABLE INSTALLATION .............................................................................................................................................. 6

HSMU/HPMU INSTALLATION, GENERAL ISSUES ................................................................................... 29

ASSEMBLY DRAWINGS ............................................................................................................................................... 29

ROUTER SETUP ........................................................................................................................................................... 29

HSMU ISSUES .............................................................................................................................................................. 36

HSMU SUCTION TUBE ASSEMBLY ............................................................................................................................ 36

HPMU ISSUES .............................................................................................................................................................. 37

VACUUM PUMP INSTALLATION ........................................................................................................................ 46

REVOLVING WORK STATION ............................................................................................................................. 51

REVOLVING WORK STATION ...................................................................................................................................... 51

EXTENSION TABLE ................................................................................................................................................... 57

CONVEYOR BELT ........................................................................................................................................................ 57

CONVEYOR BELT MECHANICS .................................................................................................................................... 57

ROLL FEEDER INSTALLATION ............................................................................................................................ 63

AIR COMPRESSOR ................................................................................................................................................ 64

VACUUM CLEANER, ZEFIRO 75, FOR HSMU / HPMU ........................................................................ 64

DIFFUSER ON AIR OUTPUT ........................................................................................................................................ 65

XP-GUIDE INSTALLATION ............................................................................................................................... 66

INSTALLING XP-GUIDE, PROCEDURE....................................................................................................................... 66

INSTALLATION ON 32/64 BIT PC ............................................................................................................... 72

ARS SOFTWARE INSTALLATION .................................................................................................................. 73

14.1 OBTAIN THE SCORPION SOFTWARE LICENSE........................................................................................................... 73

I-CUT INSTALLATION ........................................................................................................................................ 89

INSTALL XL-GUIDE ................................................................................................................................................... 89

How to get started

Short form introduction

How to prepare for installation

Context sensitive help

Technical information for special purpose

How to run HWT900xp test programs

Technical information aimed for service needs

A plan for customer training

Detailed description of XP maintenance requirements

Spare parts for XP, register and images

1.2 Special tools

1.3 Table installation sequence

Inspect the equipment

Inspect the customers preparation

Decide where in the room to locate the system

Verify acceptable floor level / flatness

Move the crates into the room

Unpack the equipment

Install table and traverse

Connect all cables

Mains power connection. System power up

Oil and grease check for correct lubrication

Setup and adjustments

Test run - IAT

1.4 Inspect the equipment