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Instructions
Kongsberg i-XL tables
Note
______________________________________
All rights strictly reserved. Reproduction or issue to third parties in any form whatever
is not permitted without written authority from the publisher.
Esko-Graphics Kongsberg AS
www.esko.com
P.O.Box 1016, N-3601 Kongsberg, Norway
Tel: +47 32 28 99 00 Fax: +47 32 28 85 15 / 32 28 67 63
Site Preparation Instructions Kongsberg i-XL
Table of Content
Welcome............................................................................................................................ 5
Introduction ........................................................................................................................ 5
Receive the equipment from Kongsberg............................................................................ 6
Inspection of Equipment ................................................................................................. 6
Storage ........................................................................................................................... 6
System Label .................................................................................................................. 6
Table Transport ................................................................................................................. 7
Room Preparation.............................................................................................................. 8
General ........................................................................................................................... 8
Floor covering ................................................................................................................. 8
Furniture ......................................................................................................................... 8
Work material storage..................................................................................................... 8
Workflow ......................................................................................................................... 8
Floor load........................................................................................................................ 8
Computer floor ................................................................................................................ 8
Headroom ....................................................................................................................... 9
Safety system .................................................................................................................. 10
System Layout ................................................................................................................. 11
Recommended Layout.................................................................................................. 12
Cables and hoses ......................................................................................................... 13
Connections to sheet feeder, vacuum reverse etc..................................................... 14
Equipment Specification .................................................................................................. 15
i-XL20 ........................................................................................................................... 15
Footprint, i-XL20 ........................................................................................................ 15
Packaging Specification, i-XL20................................................................................. 17
Packaging Specification, i-XL20 incl. PC/Vacuum pump ........................................... 17
i-XL24 ........................................................................................................................... 18
Footprint, i-XL24 ........................................................................................................ 18
Floor construction details, i-XL24............................................................................... 19
Floor construction details, i-XL24 with extension table .............................................. 20
Packaging Specification, i-XL24 incl. PC/Vacuum pump ........................................... 21
Packaging Specification, i-XL24................................................................................. 21
i-XL44 ........................................................................................................................... 22
Footprint, i-XL44 ........................................................................................................ 22
Packaging Specification, i-XL44 incl. PC/Vacuum pump ........................................... 24
Packaging Specification, i-XL44................................................................................. 24
Compressed Air System ............................................................................................... 25
Vacuum System............................................................................................................ 26
Pumps delivered to the different table models ........................................................... 26
Recommended mains fuses for the different vacuum pump models ......................... 27
Electrical connection, vacuum, principal drawing....................................................... 27
Vacuum Pump 60 Hz, Rietschle SAP 150 1,3 kW ........................................................ 29
Dimensions ................................................................................................................ 29
Requirements ............................................................................................................ 29
Noise Level ................................................................................................................ 29
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Site Preparation Instructions Kongsberg i-XL
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Site Preparation Instructions Kongsberg i-XL
All rights reserved. This material, information and instructions for use contained herein are the property of Esko-
Graphics Kongsberg AS. There are no warranties granted or extended by this document. Furthermore Esko-Graphics
Kongsberg AS does not warrant, guarantee or make any representations regarding the use, or the results of the use
of the system or the information contained herein. Esko-Graphics Kongsberg AS shall not be liable for any direct,
indirect, consequential or incidental damages arising out of the use or inability to use the system or the information
contained herein.
The information contained herein is subject to change without notice. Revisions may be issued from time to time to
advise of such changes and/or additions.
No part of this system may be reproduced, stored in a data base or retrieval system, or published, in any form or in
any way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written
permission from Esko-Graphics Kongsberg AS.
Esko-Graphics Kongsberg AS
Tordis Buen (tordis.buen@esko.com)
Kirkegårdsveien 45
N-3601 KONGSBERG
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Site Preparation Instructions Kongsberg i-XL
Welcome
Welcome to a long-lasting co-operation with Esko-Graphics.
This Site Preparation Instruction Guide is intended to provide information about the equipment
that you will receive and how to prepare the site for the installation.
Introduction
Before the Esko-Graphics Service Engineers arrive on-site to install the system, the following
items given in this handbook should be done:
♦ Prepare a suitable room for the vacuum pump. Due to its acoustic noise, the vacuum pump
should be located in a room away from people. Remember electrical supply for the vacuum
pump.
♦ Bring the crates (do not open them) containing the equipment into the destination room.
If the customer requires additional information, over and above that given here, the Esko-
Graphics Service Department will be glad to provide it.
To ensure that no damage occurs to essential parts, Esko-Graphics Service Engineers must
unpack all equipment.
Immediately after an item is unpacked, it must be inspected carefully for signs of damage.
Note
We remind you that only the ESKO-GRAPHICS staff, or persons having received an
appropriate training, are allowed to handle, manipulate or do repairs on the system.
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Site Preparation Instructions Kongsberg i-XL
Inspection of Equipment
If a crate is found to be damaged in transit, it must be left exactly as it is and the damage
reported to:
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.
Storage
While in the crates, store the equipment in a storage room, protected from weather, including
direct sunlight and extreme temperatures.
The storage temperature must be kept within -20o C to +40 o C / -4 o F to +104 o F with
humidity less than 95% RH non-condensing.
System Label
A system label as shown below is affixed to the table stand near to the Main Power Unit.
Kongsberg i-XL-24
S.no.: 258536
Power: 115V 10A 60 Hz 1000VA
Esko-Graphics Kongsberg AS
Kongsberg Norway
Made in Norway, 2003
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Site Preparation Instructions Kongsberg i-XL
Table Transport
Due to its high weight, special attention should be paid to the methods used to bring the table
into the destination room.
Note:
• These recommendations are valid for all mechanical parts.
• Pay attention to local regulations regarding safety and protective
equipments, such as protective shoes, gloves and lifting straps.
♦ Keep the table top(s) in the wooden crate(s) as long as possible. This is due also if the
table is moved vertically. While in the case, the top(s) are protected even if moved
vertically.
♦ Use forklift to bring the case into a suitable height for lifting.
♦ Be careful when the table is lifted out of the wooden case. Use wood / plastic bars to
protect the racks. Minimum height 50 mm / 2", see Appendix A.
Two methods for lifting the table top are described here:
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Site Preparation Instructions Kongsberg i-XL
Room Preparation
General
The accuracy obtained from the system depends upon room standards.
In order to maintain the high accuracy provided by the system, the instructions given here
must be adhered to.
The accuracy of the system is related to a temperature of +20 o C / +68 o F, and a relative
humidity of 50%.
However, the system can operate satisfactorily in temperatures between +10 o C and +30 o C /
+50 o F and +86 o F, and relative humidity of 30% to 80%.
Floor covering
The main criteria regarding the selection of floor-covering material is that it must be non-
static. Nylon carpets should not be used. Curtains should be non-static and lint-free.
Furniture
The furniture in the room (i.e. chairs, desks, cabinet’s etc.), additional to the system
equipment should be made of low-shedding, low static-generating materials.
Workflow
Please note the recommended material transport direction indicated in the System Layout
chapter. To obtain maximum productivity, it is important to plan material handling.
Handling heavy materials is a danger to personal health. Actions should be taken to
avoid lifting heavy materials manually.
Floor load
The floor must be level and capable of supporting an evenly distributed load of 500 kg/m² (0.7
lbs/in²). The floor must also be able to prevent the table from being subjected to vibrations.
(Most shop/office floors meet these requirements.)
Computer floor
Provided there are solid bases for table legs (e.g. concrete stands or steel beams), it is
recommended that the floor be built in the style used for computer and electronic equipment
installations. This style provides removable false-floor sections with channels underneath for
cables. Detailed information is given in the 'Equipment specification' chapter.
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Site Preparation Instructions Kongsberg i-XL
Headroom
The total height of a standard machine is specified in the chapter ‘Equipment specification’.
If the machine is equipped with a router, either FlexiHead M or MultiCut, a gallow is mounted
on the traverse as illustrated here:
2290 mm / 90 inches
Ensure the headroom is sufficient allowing the gallow to move freely.
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Site Preparation Instructions Kongsberg i-XL
Safety system
d A
Sheet
Feeder B
i-XL
d
D
Machine movement will stop and servo power will be switched off if:
• One of the light beams are broken.
• The stop mechanism is activated. A person standing too near the table activates the stop
mechanism, for instance.
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Site Preparation Instructions Kongsberg i-XL
System Layout
A recommended system layout for the different types of tables is shown in the illustration
below.
Requirements:
Recommendations:
1. Add space in front and on one side of the table to ease operation and material handling.
Furniture should be taken into account when the system layout is decided.
2. If not supplied from a central system, locate the Vacuum Pumps and Air Compressor
outside the room to reduce the noise level within the room to a minimum.
3. Although all the information is confined to the recommended layout, there are no
restrictions regarding the way the system is laid-out, except:
1. Maximum lengths of cables. If special cable length is required, these must be ordered
separately
2. The required minimum spacing is maintained.
3. The safety requirements are maintained and the safety system operates as intended.
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Site Preparation Instructions Kongsberg i-XL
Recommended Layout
i-XL
Symbol Explanation
This is the material flow direction when working with
Sheet feeder or vinyl cutting. Ensure there is enough
space in both ends of the machine to allow for proper
material handling.
When loading material manually onto the cutting table,
this is the recommended material flow direction. Ensure
there is enough space to allow for proper material
handling.
We recommend you add additional space here, allowing
the operator easy access to the whole working area.
Important, especially for the i-XL-4x series of tables. The
minimum width h = 80 cm / 2.5 ft.
This space is required also for system maintenance.
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Site Preparation Instructions Kongsberg i-XL
C V1
(1) (2) (4) (5) (3)
(10)
(11)
M (12)
(13)
(14)
MPU
Symbol Explanation
MPU Main Power Unit cabinet
El. Cable ( mains )
El. Cables ( signals )
Hoses
C Air compressor
V1 Vacuum pump
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Site Preparation Instructions Kongsberg i-XL
Plug Fuse
Item Length outside
Type supplied by Total Length
No size Cutting Table
customer
Metric Imperial Metric Imperial
1 x 115 V 20A
1 1 x 230V Yes 16A 15 m 49 ft 12 m 39 ft
(Air Compressor is optional)
Air hose for pressurised air.
2 15 m 49 ft
Air connector: 3/8 X 1/4 in.
3 Vacuum 1 control. (230V) 15 m 49 ft 12 m 39 ft
4 1 x 230V (Vacuum 1) 15 m 49 ft 12 m 39 ft
3 x 230V See
5 3 x 400V Yes separate 5m 16 ft
Mains for Vacuum pump chapter
1 X 115V 10A
6 1 x 230V Yes 5A 10 m 33 ft
Main Power Unit
7 Tube for vacuum, ø75 mm 15 m 49 ft
Network Connection
8
Customer responsible
1 x 115V / 1 x 230V (PC) 15A 1.5 m 5 ft
9 Yes
Std. PC cable 8A
10 MultiCut power, see separate chapter
11 Sheet Feeder control, see Technical manual for details.
12 Vacuum reverse control, see Technical manual for details.
13 Vacuum section control, see Technical manual for details.
14
NOTES:
1) 115V / 230V / 400V cabling outside the Cutting Table is to be provided by the Customer,
according to local standards, see chapter: Power Supply System.
2) The PC is not included in the shipment from Esko-Graphics Kongsberg AS.
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Site Preparation Instructions Kongsberg i-XL
Equipment Specification
i-XL20
Footprint, i-XL20
W2
W1
Wt
W1
Lt
Metric Imperial
Height, table top 925 mm 36,4"
Height, top of carriage, raised traverse 1340 mm 52,8"
Weight, total 405 kg 890 lbs
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Site Preparation Instructions Kongsberg i-XL
Wf
Wt
Wf
L1 L2 L3
This is the recommended layout if you have to improve the strength of your floor by steel
beams or concrete stands:
d
b b d d
a
a
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Site Preparation Instructions Kongsberg i-XL
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Site Preparation Instructions Kongsberg i-XL
i-XL24
Footprint, i-XL24
W2
W1
Wt
W1
Lt
Metric Imperial
Height, table top 925 mm 36,4"
Height, top of carriage, raised traverse 1340 mm 52,8"
Weight, total 1047 kg 2300 lbs
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Site Preparation Instructions Kongsberg i-XL
Wf
Wt
Wf
L1 L2 L3 L4
This is the recommended layout if you have to improve the strength of your floor by steel
beams or concrete stands:
c c
b b
a a a a
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Site Preparation Instructions Kongsberg i-XL
Wf
Wt
Wf
L1 L2 L3 L5 L6
Lt_ext
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Site Preparation Instructions Kongsberg i-XL
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Site Preparation Instructions Kongsberg i-XL
i-XL44
Footprint, i-XL44
W2
W1
Wt
W1
Lt
Metric Imperial
Height, table top 925 mm 36,4"
Height, top of carriage, raised traverse 1340 mm 52,8"
Weight, total 1230 kg 2700 lbs
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Site Preparation Instructions Kongsberg i-XL
Wf
Wt
Wf
L1 L2 L3 L4 L5
This is the recommended layout if you have to improve the strength of your floor by steel
beams or concrete stands:
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Site Preparation Instructions Kongsberg i-XL
d
d d
b b
a c a a c a
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Site Preparation Instructions Kongsberg i-XL
• The customer is required to install the airline that leads from the air source to the sample
room and terminate the line with a quick disconnect.
Description Requirements
Pressure 8 – 10 bar ( 8-10 kg/cm2, 8-10*105 Pa ). Constantly
above 7 bar measured locally at the outlet for the
table.
Capacity 30 l/min at 7 bar
Moisture content Dew. Point - 10o C
Purity Particle content to be less than 5 µm in any
dimension
• Air compressors make a bit of noise and should be located outside the room where the
equipment is located.
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Site Preparation Instructions Kongsberg i-XL
Vacuum System
The Vacuum System consists of:
♦ Pump(s)
Notes
♦ If the vacuum pump is supplied locally, be sure parts for installing the pump and the ø75
mm tube are available.
♦ To achieve maximum vacuum hold-down effect it is very important to avoid sharp corners
on all tubes and connectors. Use 30o bends.
♦ The service engineer will connect wires for vacuum control to the controller at the time of
installation.
i-XL20, 50Hz X
i-XL20, 60Hz X
i-XL22/24/24M/42, 50Hz X
i-XL22/24/24M/42, 60Hz X
i-XL44/46, 50Hz X
i-XL44/46, 60Hz X
Gasket applications, 50Hz X
Gasket applications, 60Hz X
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Site Preparation Instructions Kongsberg i-XL
GC800
Ma
M
R Ov
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Site Preparation Instructions Kongsberg i-XL
Abbreviations Description
M Vacuum pump motor
Ma 3 - phase, connected to motor via control relay and motor overload relay
Mc Single phase voltage for pump control
R Control relay ( ON / OFF )
Ov Motor overload relay
Notes:
The wall outlet shall meet the following requirements according to EN60204-1:
♦ Short circuit protection by fuses according to table in chapter 'Cables and hoses'.
♦ Insulation failure protection by automatic disconnection or alarm signal.
It is the customer's responsibility to prepare the electrical installation according to local
requirements.
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Site Preparation Instructions Kongsberg i-XL
Packed Unpacked
Description Metric Imperial Metric Imperial
Height 322 mm 13 inch
Width 282 mm 11 inch
Length 369 mm 15 inch
Weight 20,5 kg 45 lbs
Requirements
Description Requirements
ELECTRICAL Voltage: 230V/400V AC +10%, 3-Phases
Frequency: 60 Hz +5%.
Power: 1300VA
ENVIRON- Temperature: Operating: +10°C to +30°C / +50°F to
MENTAL +90°F
Relative Humidity: Operating: 30% to 80%
Noise Level
Description dB(A)
Average noise level, discharge connected to a 63
pipeline
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Site Preparation Instructions Kongsberg i-XL
Dimensions
Packed Unpacked
Description Metric Imperial Metric Imperia
l
Height 381 mm 15 inch
Width 332 mm 13 inch
Length 368,5mm 15 inch
Weight 29,5 kg 65 lbs
Requirements
Description Requirements
ELECTRICAL Voltage: 230V/400V AC +10%, 3-Phases
Frequency: 50 Hz +5%.
Power: 3000VA
ENVIRON- Temperature: Operating: +10°C to +30°C / +50°F to
MENTAL +90°F
Relative Humidity: Operating: 30% to 80%
Noise Level
Description dB(A)
Average noise level, discharge connected to a 65
pipeline
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Site Preparation Instructions Kongsberg i-XL
Dimensions
Packed Unpacked
Description Metric Imperial Metric Imperial
Height 443 mm 18 inch
Width 386 mm 16 inch
Length 464 mm 19 inch
Weight 44 kg 97 lbs
Requirements
Description Requirements
ELECTRICAL Voltage: 230V/400V AC +10%, 3-Phases
Frequency: 60 Hz +5%.
Power: 3600 VA
ENVIRON- Temperature: Operating: +10°C to +30°C / +50°F to
MENTAL +90°F
Relative Humidity: Operating: 30% to 80%
Noise Level
Description dB(A)
Average noise level, discharge connected to a 73
pipeline
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Site Preparation Instructions Kongsberg i-XL
Dimensions
Packed Unpacked
Description Metric Imperial Metric Imperial
Height 486 mm 20 inch
Width 432 mm 17 inch
Length 490 mm 20 inch
Weight 58 kg 128 lbs
Requirements
Description Requirements
ELECTRICAL Voltage: 230V/400V AC +10%, 3-Phases
Frequency: 50 Hz +5%.
Power: 3000VA
ENVIRON- Temperature: Operating: +10°C to +30°C / +50°F to
MENTAL +90°F
Relative Humidity: Operating: 30% to 80%
Noise Level
Description dB(A)
Average noise level, discharge connected to a 71
pipeline
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Site Preparation Instructions Kongsberg i-XL
Dimensions
Packed Unpacked
Description Metric Imperial Metric Imperial
Height 525 mm 21 inch
Width 450 mm 18 inch
Length 608 mm 24 inch
Weight 89 kg 196 lbs
Requirements
Description Requirements
ELECTRICAL Voltage: 230V/400V AC +10%, 3-Phases
Frequency: 60 Hz +5%.
Power: 6500 VA
ENVIRON- Temperature: Operating: +10°C to +30°C / +50°F to
MENTAL +90°F
Relative Humidity: Operating: 30% to 80%
Noise Level
Description dB(A)
Average noise level, discharge connected to a 71
pipeline
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Site Preparation Instructions Kongsberg i-XL
Dimensions
Packed Unpacked
Description Metric Imperial Metric Imperial
Height 561 mm 22 inch
Width 471 mm 19 inch
Length 634 mm 25 inch
Weight 86,5 kg 190 lbs
Requirements
Description Requirements
ELECTRICAL Voltage: 230V/400V AC +10%, 3-Phases
Frequency: 50 Hz +5%.
Power: 5500 VA
ENVIRON- Temperature: Operating: +10°C to +30°C / +50°F to
MENTAL +90°F
Relative Humidity: Operating: 30% to 80%
Noise Level
Description dB(A)
Average noise level, discharge connected to a 75
pipeline
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Site Preparation Instructions Kongsberg i-XL
Environmental requirements
Description Requirements
Voltage: 115V / 230V AC +10%, Single-Phase
Frequency: 50/60 Hz +5%.
Transients should not exceed 100V for 10
us.
Power: 1000 VA
The wall outlet shall meet the following requirements according to EN60204-1:
♦ Short circuit protection by fuses, max 10A.
♦ Insulation failure protection by automatic disconnection or alarm signal.
It is the customer's responsibility to prepare the electrical installation according to local
requirements.
The conductors from the mains to the units should be terminated in 10 to 20 A ground make-
first/break-last type sockets.
Each conductor should be 1.5 mm2 / 0.023 inch2, and fuses (this applies for all line voltages)
should protect live conductors. The Ground requirements of the system also apply to these
conditions.
Recommended line fuse sizes is found in the chapter: Cables and hoses.
The cables shipped with the system do not have plugs, so that the customer can connect the
type suitable for the power sockets.
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Site Preparation Instructions Kongsberg i-XL
Ground System
The Ground System serves both as a safety-ground and as the common potential reference
point for the units of the System.
The ground-leads of all the units of the system should be connected to the common ground
terminal in the mains distribution panel (cabinet) for the plant (site) wiring, and must be
connected to true ground.
Noise Level
Description dB(A)
A-weighted sound pressure level (Lpf) < 70
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Site Preparation Instructions Kongsberg i-XL
Fuse
115 / 230 V, 50/60 Hz Single phase for MultiCut motor 16 / 10 A
115 / 230 V, 50/60 Hz Single phase for vacuum cleaner 16 / 10 A
Note: If the vacuum cleaner is bought locally, a female connector for the vacuum cleaner
mains power must be supplied as well.
The wall outlet shall meet the following requirements according to EN60204-1:
♦ Short circuit protection by fuses, max 16A.
♦ Insulation failure protection by automatic disconnection or alarm signal.
It is the customer's responsibility to prepare the electrical installation according to local
requirements.
The conductors from the mains to the units should be terminated in 10 to 20 A ground make-
first/break-last type sockets.
Each conductor should be 1.5 mm2 / 0.023 inch2, and fuses (this applies for all line voltages)
should protect live conductors. The Ground requirements of the system also apply to these
conditions.
Recommended line fuse sizes is found in the chapter: Cables and hoses.
The cables shipped with the system do not have plugs, so that the customer can connect the
type suitable for the power sockets.
PC configuration
A system with MultiCut requires two serial lines from the PC; one to the cutting table and one
to the Router controller.
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Site Preparation Instructions Kongsberg i-XL
Noise Level
Description dB(A)
Vacuum cleaner 63
A-weighted sound pressure level (Lpf) 86
( Material dependant )
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Site Preparation Instructions Kongsberg i-XL
Cutting Cutting
table table
Forklift Forklift
Alternative 1 Alternative 2
This table shows the recommended strap length for the different table sizes:
Strap length 4m 6m 8m 4m 13 ft 20 ft 26 ft 13 ft
Height H 0,6 m 0,9 m 1,2 m 0,75 m 2 ft 3 ft 4 ft 2 ft
Note:
Pay attention to local regulations regarding the use of forklift for this purpose.
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Site Preparation Instructions Kongsberg i-XL
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Site Preparation Instructions Kongsberg i-XL
♦ When lifting, add people so that the load for each one is below 77 lbs / 35 kg.
♦ When lifting, do not lift by the racks or guides. Use the front and back ends of the table for
lifting as illustrated:
If, for any reason, you have to move the table after it has been removed from the wooden
crate, pay attention to the following:
♦ Be extremely careful not to hit the racks or guides in any way. Do not use racks or guides
for lifting.
♦ If the table is moved in vertical position, place wood bars along the bottom side of the
table.
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Site Preparation Instructions Kongsberg i-XL
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Site Preparation Instructions Kongsberg i-XL
43