Site Preparation Manual: Kongsberg XP Tables

Site Preparation Manual
for
Kongsberg XP tables
Note
We remind you that only the Esko staff, or persons having received
appropriate training, are allowed to handle, manipulate or do repairs on the system.
A Publication of: Esko
Copyright © 1984-2014 Esko.

This copyright does not indicate that this work has been published.
All rights strictly reserved. Reproduction or issue to third parties in

any form whatever is not permitted without written authority from the publisher.
Esko reserves the right to change specifications without notice.
Esko-Graphics Kongsberg AS
www.esko.com
Document number: D2976 P.O.Box 1016, N-3601 Kongsberg, Norway
Status: 130411 Tel: +47 32 28 99 00 Fax: +47 32 28 85 15 / 32 28 67 63
Site Preparation Instructions Kongsberg XP
Change record
07-05-2010 jhbe Ch 3.1 Inspection of equipment has been modified

09-06-2010 jhbe Added chapters about Extension table for XP20, 24, 44
15-06-2010 jhbe Added chapter about Vacuum cleaner for HSMU
10-02-2011 jhbe Revolving work station, alternative position chapter added
Table transport chapter has been modified
08-04-2011 jhbe Table transport chapter has been modified
Packaging specification chapters have been modified
22-10-2011 jhbe Added chapter about Zefiro 75 vacuum cleaner for HSMU
23-05-2012 jhbe HPMU (High Power Milling Unit) has been added
05-06-2012 jhbe Extension table information added
04-07-2012 jhbe Fuse size update
04-07-2012 jhbe XP44 including HSMU/HPMU, footprint updated
16-10-2012 jhbe Vacuum extern kit information added
11-03-2013 jhbe HPMU chiller temperature requirements updated
06-04-2013 jhbe Headroom for gallows has been increased
11-04-2013 jhbe Length of power cable and suction hose for vacuum cleaner modified
© 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
Kirkegårdsveien 45
N-3616 KONGSBERG
2
Table of Content
1 Welcome......................................................................................................................... 6
2 Introduction .................................................................................................................... 6
3 Receive the equipment from Kongsberg .............................................................................. 7
3.1 Inspection of Equipment .............................................................................................. 7
3.2 Storage ..................................................................................................................... 7
3.3 System Label ............................................................................................................. 7
4 Table Transport ............................................................................................................... 8
5 Room Preparation ............................................................................................................ 9
5.1 General ..................................................................................................................... 9
5.2 Floor covering ............................................................................................................ 9
5.3 Furniture ................................................................................................................... 9
5.4 Work material storage................................................................................................. 9
5.5 Workflow ................................................................................................................... 9
5.6 Floor load and level .................................................................................................... 9
5.7 Computer floor ......................................................................................................... 10
5.8 Headroom ............................................................................................................... 10
6 Noise level .................................................................................................................... 11
7 DynaGuard safety system ............................................................................................... 11
8 System Layout .............................................................................................................. 12
8.1 Introduction ............................................................................................................ 12
8.2 Recommended Layout with DynaGuard safety system ................................................... 13
8.3 Cables, hoses and fuses ............................................................................................ 14
8.3.1 XP .................................................................................................................... 14
8.3.2 XP including HSMU, additions ............................................................................... 15
8.3.3 XP including HPMU, additions ............................................................................... 15
8.3.4 Symbols used in figures ....................................................................................... 16
8.3.5 Specifications ..................................................................................................... 17
9 Equipment Specification ................................................................................................. 18
9.1 XP20 ...................................................................................................................... 18
9.1.1 Overall dimensions, XP20 .................................................................................... 18
9.1.2 Footprint, XP20 .................................................................................................. 18
9.1.3 XP20 with HSMU/HPMU ....................................................................................... 19
9.1.4 XP20 dimension tables ........................................................................................ 19
9.1.5 Packaging Specification, XP20 .............................................................................. 20
9.2 XP24 ...................................................................................................................... 21
9.2.2 Footprint, XP24 .................................................................................................. 21
9.2.3 XP24 with HSMU/HPMU ....................................................................................... 22
9.3 XP44 ...................................................................................................................... 24
9.3.2 Footprint, XP44 .................................................................................................. 24
9.3.3 XP44 with HSMU/HPMU ....................................................................................... 25
9.4 XP with Extension table ............................................................................................. 27
9.4.1 XP20 with Extension table .................................................................................... 27
9.4.4 Extension table dimensions .................................................................................. 30
9.4.5 Extension table weight ........................................................................................ 30
9.5 XP with sheet feeder ................................................................................................. 31
9.5.1 Dimensions ........................................................................................................ 32
9.5.2 Weight .............................................................................................................. 32
3
9.6 The Front End PC ..................................................................................................... 33

9.6.1 Dimensions ........................................................................................................ 33
9.6.2 Requirements ..................................................................................................... 33
9.6.3 Configuration of Front End PC............................................................................... 33
9.6.4 Specification ...................................................................................................... 34
9.7 The Revolving Work Station ....................................................................................... 35
9.7.1 Dimensions ........................................................................................................ 35
9.7.2 Revolving work station ........................................................................................ 35
9.7.3 Revolving work station, alternative position ........................................................... 36
9.8 Roll holder ............................................................................................................... 37
9.9 Roll feeder ............................................................................................................... 37
9.10 Compressed Air System.......................................................................................... 38
9.10.1 The Air source outlet ........................................................................................ 38
9.10.2 The Air source specifications: ............................................................................ 38
9.10.3 Guidelines to the customer when purchasing a compressor ................................... 39
9.11 Vacuum System .................................................................................................... 40
9.11.1 Introduction .................................................................................................... 40
9.11.2 Vacuum pumps for the different table models ...................................................... 41
9.11.3 Vacuum extern kit, content ............................................................................... 41
9.11.4 Recommended mains fuses/cable dimensions ...................................................... 42
9.11.5 Electrical connection, vacuum, principal drawing .................................................. 43
9.11.6 Technical information, Busch vacuum pumps ....................................................... 44
9.11.7 Sound suppression for vacuum pump ................................................................. 45
9.12 Vacuum pump with E-save ..................................................................................... 46
9.12.1 Installation...................................................................................................... 46
9.12.2 Electrical requirements ..................................................................................... 47
9.12.3 Physical dimensions ......................................................................................... 47
9.13 Cutting table with controller .................................................................................... 48
9.13.1 Environmental requirements.............................................................................. 48
9.13.2 Mains Power Requirements ................................................................................ 48
9.13.3 Direct Mains Connection.................................................................................... 48
9.13.4 Ground System ................................................................................................ 48
9.13.5 Un-interruptible Power Supply ........................................................................... 48
9.13.6 Noise Level ..................................................................................................... 49
9.13.7 Configuration of Front End PC ............................................................................ 49
9.14 HSMU / HPMU tool head ......................................................................................... 50
9.14.3 Pressurized Air requirements ............................................................................. 50
9.14.4 PC configuration .............................................................................................. 50
9.14.5 Noise Level ..................................................................................................... 50
9.15 Chiller unit for HPMU .............................................................................................. 51
9.16 Mains Power Requirements ..................................................................................... 51
9.17 Direct Mains Connection ......................................................................................... 51
9.18 Air input / output .................................................................................................. 52
9.19 Vacuum cleaner DBFV for HSMU .............................................................................. 53
9.20 Vacuum cleaner, Zefiro 75, for HSMU / HPMU............................................................ 54
9.20.3 Diffuser on air output ....................................................................................... 54
9.21 Direct mains connection, guidelines ......................................................................... 55
4
5
1 Welcome
Welcome to a long-lasting co-operation with Esko.
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.
Note: Some of the equipments described in this manual are optional.
2 Introduction
Before the Service Engineers arrive on-site to install the system, the following items given in this
handbook should be done:
 Prepare the installation room.
 Prepare all electrical supplies.
 Prepare compressed air supply. If an air compressor is delivered from Esko, a suitable place
for the unit should be prepared.
 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 properly done, this preparation permits the system to be commissioned as quickly as possible.
The less time spent on the installation the more time our engineer can spend with department
designers and/or table operator(s) training them on system operation.
If the customer requires additional information, over and above that given here, the Esko Service
Department will be glad to provide it.
To ensure that no damage occurs to essential parts, Esko Service Engineers must unpack all
equipment.
Under no circumstances must either crates or boxes be opened with crowbars or similar
tools, this can cause damage to the contents.
Immediately after an item is unpacked, it must be inspected carefully for signs of damage.
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.
6
3 Receive the equipment from Kongsberg
3.1 Inspection of Equipment

In case of visual damage to one or more of the crates upon delivery, a note/remark should be made
on the receipt of the forwarder and the forwarder should be notified.
Shipper shall be informed about the damage, and the signed receipt with remark should be sent to
the shipper. The signed receipt is very important as proof of damage in case there is damage to the
contents of the shipment for the further processing of the case.
Photos should be made of the damage, preferably before the goods are unloaded from the truck. The
photos need to be sent to the shipper.
The goods are not to be opened without the presence of qualified Esko Engineer or partners. If
damage is found while unpacking the unit the service people of Esko need to make photos of this
and sent it to shipper.
3.2 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.
3.3 System Label

A system label as shown below is affixed to the table stand near to the Main Power Unit (sample)
XP24 Cutting table, s.no: 703700

Prod: 02-2011
Made in Norway.
El.schem: 255620/256524
Fuse in installation 12A/6kA
Complies with FCC rules, part 15, class B
Laser class 2 confirms to 21CFR1040.10
Esko-Graphics Kongsberg AS,
P.O. Box 1016, 3601 Kongsberg, Norway
Power: 230V 6,25A 50/60Hz 1400W single ph.
7
4 Table Transport
Due to its high weight, special attention should be paid to the methods used to bring the table tops
into the destination room.
Typical weights (one table section):
XP20 XP24 XP44

kg lbs kg lbs kg lbs
235 520 235 520 285 630
Note:
 Recommendations are valid for all mechanical parts.
 Adhere to local regulations regarding lifting safety.
 Adhere to local regulations regarding protective equipments, such as protective
shoes and gloves.
Please follow the recommended rules:
 Keep the table top(s) in the wooden crate(s) as long as possible. 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 protection bars to protect
the racks. Minimum height 50 mm / 2 in.; included in the shipment.
 When lifting, do not lift by the

racks or guides. Use the front and
back ends of the table for lifting as
illustrated.
 Be extremely careful not to hit the

racks or guides in any way.
 If the table is moved in vertical

position, place protection bars
along the bottom side of the table.
If installation according to local regulations and the requirements listed here are not possible, a firm
of movers should be hired.
8
5 Room Preparation
5.1 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%.
5.2 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.
5.3 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.
5.4 Work material storage

The conditions under which materials are stored are also important where accuracy is concerned.
Assuming an air-conditioned room is provided for the Cutting System, we recommend that the
material to be used be stored in a room with the same conditions as the cutting room.
5.5 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.
5.6 Floor load and level

The floor must be level and capable of supporting an evenly distributed load of 500 kg/m² (0.7
lbs/in²). The flatness of the floor area prepared for the machine should be within +/- 5 mm
(+/- 0.2 in.).
The floor must also be able to prevent the table from being subjected to vibrations. (Most
shop/office floors meet these requirements.)
9
5.7 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.
5.8 Headroom
The total height of a standard machine is specified in the chapter „Equipment specification‟.
If the machine is equipped with a HSMU (High Speed Milling Unit) or HPMU (High Power Milling
Unit), a gallows is mounted on the right-hand side of the table:
Hg
Ensure the headroom is sufficient allowing the gallows to move freely.
Hg
mm Inch
XP20 3000 118
XP24 3000 118
XP44 3000 118
10
6 Noise level
The XP system generates a noise that can be hazardous if people have to work nearby the machine
over time.
The noise level should be taken into account when the room and machine location is planned.
For the operators, hearing protection should be available and used.
7 DynaGuard safety system
The DynaGuard safety system consists of four light beams, two in front of the traverse and two
behind. In addition, there is a stop mechanism mounted on each end of the traverse.
Machine movement will stop and servo power will be switched off if:
 One of the light beams is broken.
 The stop mechanism is activated. A person standing too near the table activates the stop
mechanism, for instance.
11
8 System Layout
8.1 Introduction
A recommended system layout for the different types of tables is shown in the illustration below.
Requirements:
1. A minimum spacing between the equipment and walls.
2. A minimum spacing between the units required by maintenance personnel.
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. For operator convenience, the PC should be located close to the table and the operator panel.
3. 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.
4. 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.
12
8.2 Recommended Layout with DynaGuard safety system
W1
Wtp
W2
L2 Lt L1
Distance Metric Imperial

L1 min 50 cm min 1.7 ft
L2 110 cm 3,7 ft
Lt See table dimensions. See table dimensions.
W1 (see note 1) min 80 cm min 2,7 ft
W2 125 cm 4,2 ft
Wtp See table dimensions. See table dimensions.
Notes
1 We recommend you add additional space on this side of the table, due to:
 For the operator, provide easy access to the whole working area. Important, especially
for the XP4x series of tables.
 For customer service – ease access to controller unit.
13
8.3 Cables, hoses and fuses
8.3.1 XP
8
V
7
1 2 3 4 5 6
C
MPU
M
14
8.3.2 XP including HSMU, additions
10 11 12 13
Inverter MPU
M
8.3.3 XP including HPMU, additions
10 11 14 15 16 12 13
Inverter MPU
M
15
8.3.4 Symbols used in figures

Symbol Explanation
MPU Main Power Unit cabinet
El. Cable ( mains single phase )
El. Cable ( mains, three phase )
El. Cable (network cable)
Hoses (vacuum, pressurized air)
Water tubes
Recommended transport direction for material
Air compressor
C
V Vacuum pump
Air regulator and manometer

M
Vacuum cleaner for HSMU/HPMU
Chiller unit for HPMU
Yellow / Black tape on the floor to indicate attention area.
16
8.3.5 Specifications
Plug
Item Voltage / Fuse supplied Length outside
Description Total Length
No size by Cutting Table
customer
1.5 m 5 ft
1 x 115V / 10A
1 Power for PC, screen Yes Std. PC Std. PC
1 x 230V / 5A
cable cable
Network Connection
2
Customer responsible
1 x 115V / 15A
3 Mains for Cutting table (MPU) Yes 10 m 33 ft
1 x 230V / 6.25A
4 Vacuum control signal 1 x 230V 15 m 49 ft 12 m 39 ft
5 Tube for vacuum ø75 mm 15 m 49 ft
Air hose for pressurised air.

6 15 m 49 ft
Air connector: 3/8 X 1/4 in.
Mains for air Compressor 1 x 115V / 20A

7 Yes 15 m 49 ft 12 m 39 ft
(Air Compressor is optional) 1 x 230V / 16A
3 x 230V, 3 x 400V
8 Mains for Vacuum pump Yes 5m 16 ft
See separate chapter
1 x 115V / 5A
9 Power for vacuum control relay Yes 15 m 49 ft 12 m 39 ft
1 x 230V / 5A
1 x 115V / 16A
10 Mains for Ibag Inverter 15 m 49 ft 12 m 39 ft
1 x 230V / 10A
3 x 230V / 20A
11 Mains for vacuum cleaner Yes 15 m 49 ft 12 m 39 ft
3 x 400V / 10A
12 Power for vacuum cleaner 10 m 33 ft 10 m 33 ft
13 Suction hose, vacuum cleaner 10 m 33 ft 10 m 33 ft
1 x 115V / 16A
14 Mains for chiller 15 m 49 ft 12 m 39 ft
1 x 230V / 10A
15 Chiller power 15 m 49 ft 12 m 39 ft
16 Chiller water tubes (f/r) 15 m 49 ft 12 m 39 ft
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.
17
9 Equipment Specification
9.1 XP20
9.1.1 Overall dimensions, XP20
Wa24 Lt20
Wt24
Wp24
9.1.2 Footprint, XP20
Lt20
L120 L2 L120
Wb24
Wp
Lp
18
9.1.3 XP20 with HSMU/HPMU
Lt20
Wa24
Wtmur24
Wp24
Wpw24
9.1.4 XP20 dimension tables
Distance mm Inch Distance mm Inch
b 300 11,8 Wa24 1870 73,6

L120 480 18,9 Wb24 1795 70,7
L2 1120 44,1 Wp 925 36,4
Lp 750 29,5 Wp24 3562 140,2
Lt20 2080 81,9 Wpw24 Min. 800 32
Wtmur24 2960 116,5
Wt24 2732 107,6
Metric Imperial
Height, table top 877 mm 34.5 "
Height, top of carriage 1432 mm 56.4 "
Weight, total ≈900 kg ≈1980 lbs
19
9.1.5 Packaging Specification, XP20

Crates Height, H Width, W Length, L Weight Net weight
mm inch mm inch mm inch kg lbs kg lbs
1 Table Top 360 14,2 1950 76,8 2190 86,2 325 715 235 517
2 Traverse / Misc 1050 41,3 790 31,1 2790 109,8 245 539 175 385
3 Frame / Misc 940 37,0 1320 52,0 2410 94,9 610 1342 495 1089
20
9.2 XP24
Lt24
Wa24
Wt24
Wp24

Lt24
L1 L2 L3 L2 L1
Wb24
Wp
Lp
21
Lt24
Wa24
Wtmur24
Wp24
Wpw24

b 300 11,8 Wa24 1870 73,6
L1 518 20,4 Wb24 1795 70,7
L2 1120 44,1 Wp 925 36,4
L3 605 23,8 Wp24 3562 140,2
L4 --- --- Wpw24 Min. 800 32
Lp 750 29,5 Wtmur24 2960 116,5
Lt24 3880 152,8 Wt24 2732 107,6
Metric Imperial
22
1 Table Top: 360 14,2 1950 76,8 2050 80,7 295 649 220 484
2 Table Top: 360 14,2 1950 76,8 2050 80,7 295 649 220 484
3 Frame / misc 930 36,6 1320 52,0 1910 75,2 415 913 330 726
Traverse / 41,3 31,1 109,8 869 325 715

4 1050 790 2790 395
misc
5 Frame / misc 930 36,6 1320 52,0 1910 75,2 270 594 185 407
23
9.3 XP44
Wa44 Lt44
Wt44
Wp44

Lt44
L1 L2 L3 L2 L1
Wb44
Wp
Lp
24

Lt44 3880 152,8 Wt44 3262 128,4
L1 518 20,4 Wa44 2397 94,4
L2 1120 44,1 Wb44 2325 91,5
L3 605 23,8 Wp44 4093 161,1
L4 --- --- Wpw44 Min. 800 32
Lp 750 29,5 Wtmur44 3450 136
Wp 925 36,4
b 300 11,8
Metric Imperial
25
1 Table Top: 360 14,2 2060 81,1 2480 97,6 370 814 285 627
2 Table Top: 360 14,2 2060 81,1 2480 97,6 370 814 285 627
3 Frame / misc 940 37,0 1320 52,0 2410 94,9 260 572 145 319
Traverse /
4 1020 40,2 810 31,9 3320 130,7 240 528 135 297
misc
5 Frame / misc 940 37,0 1320 52,0 2410 94,9 330 726 215 473
26
9.4 XP with Extension table

L2ext
9.4.1 XP20 with Extension table
L20ext0
XP20 +
conveyor belt
L20ext1
L2ext
XP20 +
conveyor belt +
one full size unload extension table
L20ext2
L2ext
XP20 +
conveyor belt +
one full size load extension table
L20ext3
L2ext L2ext
XP20 +
conveyor belt +
one full size load extension table +
27
L24ext0
XP24 +
conveyor belt
L24ext1
L2ext
XP24 +
conveyor belt +
one half size unload extension table
L24ext2
L2ext
XP24 +
conveyor belt +
one half size load extension table
L24ext3
L2ext L2ext
XP24 +
conveyor belt +
one half size load extension table +
L24ext4
L2extx2
XP24 +
conveyor belt +
28
L44ext0
XP44 +
conveyor belt
L44ext1
L4ext
XP44 +
conveyor belt +
L44ext2
L4ext
XP44 +
conveyor belt +
one half size load extension table
L44ext3
L4ext L4ext
XP44 +
conveyor belt +
one half size load extension table +
L44ext4
L4extx2
XP44 +
conveyor belt +
29
9.4.4 Extension table dimensions
mm inch mm inch
L20ext0 2300 91 L44ext0 4100 162
L20ext1 4060 160 L44ext1 5860 231
L20ext2 4060 160 L44ext2 5860 231
L20ext3 5840 230 L44ext3 7640 301
L44ext4 7640 301
L24ext0 4100 162
L24ext1 5860 231 L4ext 1860 74
L24ext2 5860 231 L4extx2 3580 141
L24ext3 7640 301
L24ext4 7640 301
L2ext 1860 74
L2extx2 3580 141
9.4.5 Extension table weight
XP20 XP24 XP44

Extension
60 130 60 130 80 170
table
30
9.5 XP with sheet feeder
Wlt
Load table
Llt
Wsf
115/230V for Sheet Feeder

Lxp
Lsft
Pressurized air
115/230 V for PC
115/230 V for screen
115/230 V for XE (MPU)
Network
Wlt
Unload table
Llt
Llt
31
9.5.1 Dimensions
XP20 XP24 XP44

mm inch mm inch mm inch
Llt 1575 62 1575 62 1575 62
Lxp 2200 87 4000 158 4000 158
Lsft 5800 229 7600 300 7600 300
Wlt 1950 77 1950 77 2350 93
Wsf 925 37 925 37 925 37
9.5.2 Weight
XP20 XP24 XP44

Sheet
230 500 250 500 250 550
feeder
Load/
unload 50 110 50 110 80 180
table
32
9.6 The Front End PC

The Front End PC is shipped in the same box as the table bases.
In the XP system, the Front End PC is located inside the Revolving Work Station.
9.6.1 Dimensions
Description Metric Imperial
Height 162 mm 7 inch
Width 439 mm 18 inch
Depth 540 mm 22 inch
Weight 15 kg 33 lbs
9.6.2 Requirements
Description Requirements
Voltage: 115V / 230V AC +10%, Single-Phase
50/60 Hz +5%.
ELECTRICAL Frequency:
Transients should not exceed 100V for 10 us.
Power: 450 VA
Operating: +5°C to +32°C
ENVIRON- Temperature:
+41°F to +90°F
MENTAL Operating: OFF: 20% to 80%
Relative Humidity:
ON: 8% to 80%
9.6.3 Configuration of Front End PC

For the control system to work properly, it is a requirement that the operator has “Administrator
privileges” setup on the Front End PC.
33
9.6.4 Specification
General specifications to be met by a front end PC:
Subject Requirements
Chassis Standard base Desktop Chassis
The PC must be ARS/XL-register Firewire card,
prepared for the Unibrain FireBoard-Blue, PCI, low profile
following insert
i-cut Video card: PIXCI SV5 PCI Full height
modules:
Video card: PIXCI SV7 PCI Express, low profile
(from Jan. 1, 2011).
Memory >= 1GB
Hard Drive >= 10GB (depending upon the applications to be installed)
Optical Drive CD/DVD
Serial line One serial line for cutting table.
One serial line for IBAG inverter (HSMU/HPMU).
One serial line for sheet feeder communication (solved using USB to
serial adapter).
Display >= 17 inch (1280X1024)
Operating System Microsoft Windows XP Professional or
Microsoft Windows 7 Professional
34
9.7 The Revolving Work Station

The work station will be shipped in the same box as the table bases, partly assembled.
9.7.1 Dimensions
Wrev
Drev
Wpc
Hpc
Hrev
Description Metric Imperial

Hrev 550 mm 21.6 inch
Wrev 690 mm 27.2 inch
Drev 680 mm 26.8 inch
Wpc 150 mm 5.9 inch
Hpc 430 mm 16.9 inch
Weight kg
9.7.2 Revolving work station

The work station top can be rotated 90o.
35
9.7.3 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.
If HSMU / HPMU is included in the installation,

we recommend using RWS standard position in
order to maintain easy access to the table.
36
9.8 Roll holder
Total machine length is extended by 300

mm / 12 in. plus space for roll handling.
9.9 Roll feeder
Total machine length is extended by 600

mm / 24 in. plus space for roll handling.
37
9.10 Compressed Air System

The Compressed Air System consists of:
 Air Source; Industry Pressurized Air or dedicated Air Compressor.

 Connection Hose
 Air Regulator Valve.
 The customer is required to provide the pressurized air source.
 The customer is required to install the airline that leads from the air source to the table room and
terminate the line with a quick connector.
9.10.1 The Air source outlet

An outlet for compressed air connection should be located in a position where it is visible from the
equipment.
Alternatively, a lockable compressed air ON/OFF switch can be installed.
This to avoid that compressed air accidentally being switched on while maintenance is carried out.
All installations should be according to local regulations.
9.10.2 The Air source specifications:

Metric Imperial
Capacity at 7 bar
Running all tools, except HSMU / HPMU 30 l/min 1 cfm
Running HSMU / HPMU 80 l/min 3 cfm
Running Sheet Feeder (1) 140 l/min 5 cfm
8 – 10 bar ( 8-10 kg/cm , 8-10*105 Pa ).
2
Pressure Constantly above 7 bar measured locally

at the outlet for the table.
Moisture content Dew. Point - 10o C
Particle content to be less than 5 µm in
Purity
any dimension
(1) Measured with 4 suction cups and 2 air knives. Air consumption depends upon the
number of air knives and number of suction cups.
38
9.10.3 Guidelines to the customer when purchasing a compressor
The surface of the compressor gets hot.

Ensure there is enough free space around
the compressor.
Picture shows a compressor top view, A >=

1 m / 40 inches.
 Air compressors make a bit of noise and should be located outside the room where the
equipment is located. Typical noise level 84 db(A).
 The compressor should be installed according to local regulations.
 The recommended minimum air container volume is 50l.
 Operating temperature 0°C to +32°C / +32°F to +90°F
39
9.11 Vacuum System
9.11.1 Introduction
The Vacuum System consists of:
 Pump(s)
 Connection Tube(s), diameter 75 mm.
Notes
 The pump(s) should be located outside the room as recommended.
 If the vacuum pump is supplied locally, be sure parts for installing the pump and the ø75 mm
tubes 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.
 Pump cables are delivered without connectors for wall outlet.
 The service engineer will connect wires for vacuum control to the controller at the time of
installation.
 Never locate the pump underneath the cutting table:
40
9.11.2 Vacuum pumps for the different table models
Busch SB 0710 D 5,5 kW – 50 Hz

XP20 x x
XP24 x x
XP44 x x
x) Vacuum pump from this size and up is recommended.
9.11.3 Vacuum extern kit, content
41
9.11.4 Recommended mains fuses/cable dimensions

Pump Eff. Part.no 3xV Hz A Recomm- Recomm-
kW ended cable ended mains
dimensions fuses (A)
(mm2)
SB 0200 D 1,5 42446104 230V 1-ph 50 11 2,5 20
SB 0310 D 2,2 42446187 230V 1-ph 50 12,8 2,5 20
SB 0310 D 2,2 42446112 230V () 50 10 2,5 20
SB 0310 D 2,2 42446112 400V () 50 5,8 2,5 16
SB 0430 D 3,0 42446120 230V () 50 12,5 4,0 25
SB 0430 D 3,0 42446120 400V () 50 7,2 4,0 16
SB 0710 D 5,5 42446138 230V () 50 23,5 6,0 35
SB 0710 D 5,5 42446138 400V () 50 13,6 6,0 32
SB 0710 D 7,5 42446146 230V () 50 30,8 6,0 50
SB 0710 D 7,5 42446146 400V () 50 17,6 6,0 35
SB 0200 D 2,1 42446153 230V () 60 7,6 2,5 16
SB 0200 D 2,1 42446153 400V () 60 4,4 2,5 10
SB 0430 D 3,5 42446161 230V () 60 12,6 4,0 25
SB 0430 D 3,5 42446161 400V () 60 7,3 4,0 16
SB 0530 D 6,3 42446179 230V () 60 23,5 6,0 35
SB 0530 D 6,3 42446179 400V () 60 13,6 6,0 32
42
9.11.5 Electrical connection, vacuum, principal drawing
Mc
GC800
Ma
M
R Ov
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.
43
9.11.6 Technical information, Busch vacuum pumps
L W
SB SB SB SB SB SB SB SB SB
0200 D 0310 D 0310 D 0430 D 0710 D 0710 D 0200 D 0430 D 0530 D
1/3 - phase 1 1 3 3 3 3 3 3 3
230/ 230/ 230/ 230/ 230/ 230/ 230/

Voltage +/-10% 230V 230V
400V 400V 400V 400V 400V 400V 400V
Hz +/- 5% 50 50 50 50 50 50 60 60 60
Power (kW) 1,5 2,2 2,2 3,0 5,5 7,5 2,1 3,5 6,3
Length L (mm) 317 352 352 361 496 496 317 361 496
Width W (mm) 336 383 383 383 500 500 336 383 500
Height H (mm) 340 386 386 386 516 516 340 386 516
Length L (inch) 12,5 13,9 13,9 14,3 19,6 19,6 12,5 14,3 19,6
Width W (inch) 13,3 15,1 15,1 15,1 19,7 19,7 13,3 15,1 19,7
Height H (inch) 13,4 15,2 15,2 15,2 20,4 20,4 13,4 15,2 20,4
Outlet D G2 G2 G2 G2 G 2,5 G 2,5 G2 G2 G 2,5
Weight (kg) 21 29 29 34 126 128 21 34 114
Weight (lbs) 47 64 64 75 278 282 47 75 251
Average noise
level, exhaust
64 69 69 70 70 70 70 73 74
connected to a
pipeline, db(A)
Temperature: Operating: +0°C to +30°C / +32°F to +90°F
Relative
Operating: 30% to 80%
Humidity:
44
9.11.7 Sound suppression for vacuum pump

An optional sound suppression box for the vacuum pump is available.
W L
Metric (mm) Imperial (inches)

L W H L W H
Sound suppression box 900 900 700 35 35 28
Warm
air
output
Sound supression cabinet
Warm
air
output
45
9.12 Vacuum pump with E-save
MPU
Vacuum on/off (12m / 39 ft. outside machine)

400V
4-20 mA 0-60Hz
Vacuum Vac. level
sensor
50mm
2 in.
Vacuum pump controlled by a variable frequency drive (VFD) is available as an option using Vacon
inverter.
9.12.1 Installation
BA CK
RES ET
OK
Inverter
3
1
Mains 3
Vacuum
On/off control 2 sensor
(MPU)
4
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: The inverter is generating noise, thus it is recommended to mount the inverter together with
the vacuum pump in a separate room.
46
9.12.2 Electrical requirements

Plug
Item supplied Fuse Length outside
Type Total Length
No by size Cutting Table
customer
1 3 x 400V Mains vac. pump Yes 20A 5m 16 ft - -
2 Vacuum on/off control cable No - 15 m 49 ft 14 m 45 ft
3 Motor cable No - 3m 10 ft - -
4 Vacuum sensor cable No - 15 m 49 ft - -
9.12.3 Physical dimensions

Wv Dv
W1
BACK
RESET
H1 Hv
mm In. mm In.
Wv 144 5,7 W1 115 4,5
Dv 214 8,4 H1 406 16,0
Hv 419 16,5
47
9.13 Cutting table with controller
9.13.1 Environmental requirements

Temperature: Operating: +10°C to +30°C / +50°F to +86°F
Relative Humidity: Operating: 30% to 80%
1) See also chapter: Room preparation, General

2) If HPMU is included, see special temperature requirements for chiller.
9.13.2 Mains Power Requirements

Voltage: 115V / 230V AC +10%, Single-Phase
Frequency: 50/60 Hz +5%.
Transients should not exceed 100V for 10 us.
Power: 1000 VA
9.13.3 Direct Mains Connection

See chapter Direct mains connection, guidelines (55).
9.13.4 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.
9.13.5 Un-interruptible Power Supply

Depending upon the stability of the mains supply, an UPS-device (Un-interruptible Power Supply) is
recommended. If installed, both the Front-End PC and the cutting table (MPU) should be connected
to the UPS.
Other devices, as air compressor, vacuum cleaner, controller for HSMU / HPMU spindle should
connect directly to a wall outlet.
The capacity of a UPS – device should be ≈ 1000 W.
48
9.13.6 Noise Level

A-weighted sound pressure level.
Description
(Material dependant) dB(A)
Table running silent tooling, average 78.5 – 83.5
Running High Freq. VibraCut knife tool, average 78.5 – 83.5
Table running, peak level 98.5 dB(A)
9.13.7 Configuration of Front End PC

For the control system to work properly, it is a requirement that the operator has “Administrator
privileges” setup on the Front End PC.
49
9.14 HSMU / HPMU tool head

Voltage: 115/230V AC +10%, 1-Phase
Power, HSMU 1000 VA
Power, HPMU 3000 VA

9.14.3 Pressurized Air requirements

For HSMU / HPMU, it is important that the pressurized air level is constantly above 7 bar measured
locally at the outlet for the table. For details, see chapter: „Compressed Air System‟.
9.14.4 PC configuration
A system with HSMU /HPMU requires two serial lines from the PC; one to the cutting table and one
to the HSMU / HPMU controller.
9.14.5 Noise Level

Description dB(A)
Vacuum cleaner 63
A-weighted sound pressure level (Lpf) 86
( Material dependant )
50
9.15 Chiller unit for HPMU

Dimensions:
Mains
Signal Lch=700 mm,
Wch=510 mm,
Lch
height 440 mm / 27,5 x 20 x 17.3 in.
Water
in/out Environmental requirements:
Wch Temperature:
Operating: +15°C to +41°C / +59°F to +106°F
Note:
The low temperature limit is critical for proper operation.
Do not locate the chiller unit underneath the

cutting table.
Within shown limits, the chiller can be located

above or beneath cutting table level.
3m/
10 ft.
3m/
10 ft.
9.16 Mains Power Requirements

Voltage: 115/230V AC +10%, 1-Phase
Power: 2000 VA
9.17 Direct Mains Connection

51
9.18 Air input / output

Assure free space 0,5 m / 20 in. on the air input side.
Assure free space 1 m / 40 in. on the air output side.
52
9.19 Vacuum cleaner DBFV for HSMU
H1
W1
mm inch
W1 420 17
H1 1500 59

Voltage: 230V / 380V AC +10%, 3-Phase
Power: 1500 VA

53
9.20 Vacuum cleaner, Zefiro 75, for HSMU / HPMU

Dimensions:
620 x 800 mm, height 1650 mm / 24.4 x 31.5 in, height 65 in.

Voltage: 230V / 380V AC +10%, 3-Phase
Power: 2200 VA

9.20.3 Diffuser on air output

Included in the shipment is an air diffuser, ready to
be mounted onto the suction unit output.
54
9.21 Direct mains connection, guidelines

A wall outlet for mains connection should be located in a position where it is visible from the
equipment. Alternatively, a lockable Main Power ON/OFF switch can be installed. This to avoid main
power accidentally being switched on while maintenance is carried out.
All installations should be according to local regulations.
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.
55

Site Preparation Manual: Kongsberg XP Tables

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A Publication of: Esko

Copyright © 1984-2014 Esko.

All rights strictly reserved. Reproduction or issue to third parties in

Esko reserves the right to change specifications without notice.

07-05-2010 jhbe Ch 3.1 Inspection of equipment has been modified

All rights reserved.

This document supersedes all previous dated versions.

Correspondence regarding this publication should be forwarded to:

9.6 The Front End PC ..................................................................................................... 33

Welcome to a long-lasting co-operation with Esko.

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

 Prepare the installation room.

 Prepare all electrical supplies.

3 Receive the equipment from Kongsberg

3.1 Inspection of Equipment

3.3 System Label

XP24 Cutting table, s.no: 703700

Typical weights (one table section):

XP20 XP24 XP44

Please follow the recommended rules:

 When lifting, do not lift by the

 Be extremely careful not to hit the

 If the table is moved in vertical

5.2 Floor covering

5.4 Work material storage

5.6 Floor load and level

5.7 Computer floor

Ensure the headroom is sufficient allowing the gallows to move freely.

7 DynaGuard safety system

1. A minimum spacing between the equipment and walls.

2. A minimum spacing between the units required by maintenance personnel.

8.2 Recommended Layout with DynaGuard safety system

Distance Metric Imperial

8.3 Cables, hoses and fuses

8.3.2 XP including HSMU, additions

8.3.3 XP including HPMU, additions

8.3.4 Symbols used in figures

Recommended transport direction for material

Air regulator and manometer

Vacuum cleaner for HSMU/HPMU

Chiller unit for HPMU

Yellow / Black tape on the floor to indicate attention area.

4 Vacuum control signal 1 x 230V 15 m 49 ft 12 m 39 ft

5 Tube for vacuum ø75 mm 15 m 49 ft

Air hose for pressurised air.

Mains for air Compressor 1 x 115V / 20A

12 Power for vacuum cleaner 10 m 33 ft 10 m 33 ft

13 Suction hose, vacuum cleaner 10 m 33 ft 10 m 33 ft

16 Chiller water tubes (f/r) 15 m 49 ft 12 m 39 ft

9.1.1 Overall dimensions, XP20

9.1.2 Footprint, XP20

9.1.3 XP20 with HSMU/HPMU

9.1.4 XP20 dimension tables

Distance mm Inch Distance mm Inch

b 300 11,8 Wa24 1870 73,6

9.1.5 Packaging Specification, XP20

9.2.1 Overall dimensions, XP24

9.2.2 Footprint, XP24

9.2.3 XP24 with HSMU/HPMU

9.2.4 XP24 dimension tables

9.2.5 Packaging Specification, XP24

Crates Height, H Width, W Length, L Weight Net weight