Isel ICP 4030 iMC-P Manuale utente

Assembly instructions for CNC basic

machines (incomplete machines)

Operating instructions for CNC machines

(complete machines)

Type/Model: ICP 4030 iMC-P

ICP 4030 iMC-P

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2018

On these operating instructions

Abbreviations

MRL Machinery Directive 2006/42/EC

Symbols used

In this manual, you will find various symbols to draw your attention to important

information / facts and risks:

Warning!

Warning of hazards that may lead to adverse health effects,

physical injury or death.

Warning! Lethal voltage

Warning of danger from electrical current. Ignoring this may lead to

serious injury or death.

Attention!

This symbol highlights instructions, which if not followed may

result in damage or malfunction.

Information

This symbol highlights important information and notices.

Safety notice

Before you start up the CNC machine ICP 4030, work with the machine or make

additions or changes to the electrical installation of the machine / in the control

cabinet /5/ of the machine, please read carefully:

•the safety notices in these operating instructions (Section 3) and

•the safety instructions for electrical drives and controls in the operating

instructions manual Positioning module with CANopen interface /1.1/ or

/1.2/

These operating instructions must be kept close to the machine and be

accessible to the staff (operators, fitters, maintenance personnel) at all times.

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rights reserved.

Despite the utmost care, printing errors and mistakes cannot be excluded. We

would be grateful for any suggested improvements or references to errors.

CE marking for (complete) CNC machines:

isel-CNC machines are CE compliant and marked accordingly. The CE

conformity declaration applies to these machines.

no CE marking for partly completed machinery:

Partly completed machinery (Definition as per Machinery Directive 2006/42/EC)

have no CE marking.

The declaration of incorporation applies to party completed machinery.

For all other machine parts and components, to which CE safety guidelines apply,

start-up is prohibited until all appropriate requirements are met.

The company isel Germany AG accepts no responsibility or liability if you make

changes to the machine without the manufacturer's consent, which affect the CE

conformity of the machine.

The EMC test is only valid for the original machine configuration delivered ex

works. Manufacturer:

isel Germany AG

Bürgermeister-Ebert-Str. 40,

D-36124 Eichenzell

Tel.: (06659) 981-700

Fax: (06659) 981-776

E-mail: automation@isel.com

http://www.isel.com

Art.-No. 970280 BD016 (Original operating instructions)

Review index

Date of

change

Reason for change

Changed

24.01.2018

Update ICP 4030

25.03.2015

Description stop key 4.3.2

03.12.2014

Serial number:

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Contents

1 Introduction......................................................................................................... 5

2 Intended use, foreseeable misuse..................................................................... 7

3 Safety notices.................................................................................................... 10

3.1 General safety notices.................................................................................10

3.2 Special safety notices..................................................................................12

4 Setting up and connecting the CNC machine................................................. 14

4.1 Scope of supply...........................................................................................14

4.2 Delivery status ex works (quality assurance) ..............................................14

4.3 Space required ............................................................................................15

4.4 Transporting the CNC machine ...................................................................16

4.5 Setting up the CNC machine .......................................................................16

4.6 Coordinate system and reference point .......................................................17

4.7 Processing machine ....................................................................................17

4.7.1 Protective cover with solenoid interlock 18

5 Design and operation ....................................................................................... 19

5.1 Safety notices..............................................................................................19

5.2 Overview .....................................................................................................20

5.3 Connections ................................................................................................21

5.3.1 Connections on the back 21

5.3.2 Front Panel Controls 22

5.3.3 Structure of the stepper motor control 23

5.4 Connections on the stepper motor controller ...............................................24

5.4.1 Safety notices 24

5.4.2 Access to the stepper motor controller and its components 24

5.4.3 Connections 25

5.5 Setting the stepper motor output stages ......................................................30

6 Installation and commissioning ...................................................................... 33

6.1 Safety notices..............................................................................................33

6.2 Preparation..................................................................................................33

6.3 Create connections......................................................................................33

6.4 Software installation ....................................................................................34

6.5 Mode AUTOmatik –Production on the CNC machine .................................36

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6.5.1 Manufacture of operational readiness 36

6.5.2 Production: Processing / manufacturing a component 41

6.5.3 Ending the operational readiness 42

6.6 Operating modes.........................................................................................43

6.6.1 Use of the ICP 4030 in CNC operation 43

6.6.2 Use of the ICP 4030 in DNC operation 44

7 Cleaning, lubrication and maintenance........................................................... 45

7.1 Cleaning ......................................................................................................45

7.2 Lubrication...................................................................................................45

7.2.1 Basic lubrication 45

7.2.2 Re-lubrication 45

7.2.3 Lubrication points of the linear axes X, Y and Z 46

7.3 Maintenance intervals according to operating hours counter .......................48

7.4 Maintenance activities .................................................................................49

8 Returning used electrical and electronic equipment for disposal ................ 50

9 Remote diagnosis ............................................................................................. 51

10 Accessories ...................................................................................................... 52

11 Technical Data ................................................................................................ 53

11.1 Dimensions and weight................................................................................53

11.2 Electrical Data .............................................................................................53

12 Malfunctions...................................................................................................... 54

13 Declaration of conformity or declaration of incorporation ........................... 55

13.1 Declaration of Conformity for (complete) machine .......................................56

13.2 Declaration of incorporation for (partly completed) basic machines .............57

14 Exploded views / spare parts lists................................................................... 58

14.1 Structure axis systems.................................................................................60

15 Source directory ............................................................................................... 66

16 Index................................................................................................................ 66

17 Annex .............................................................................................................. 68

17.1 Service card ................................................................................................68

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1 Introduction

All isel-CNC basic machines (pursuant to the Machinery Directive 2006/42/EC partly

completed machinery or partial machines) pr isel-CNC machines (pursuant to the

Machinery Directive 2006/42/EC Machinery, i.e. complete machines) of the type ICP

4030 are tried and tested CNC machines, which offer a wealth of possibilities for two or

three-dimensional machining of components.

The basis is formed by precisely tailored and variably mountable standard profiles and

drive units, which are fitted depending on the requirements of the machine type (the

so-called machine kinematics). The external appearance of the machine of one type is

always the same. The applications of the specific CNC machine in accordance with

the tool mounted (on the Z axis) can be quite diverse.

A common feature of all CNC basic machines / CNC machines of the type ICP 4030 is

the control and safety concept and the basic structure of the mechanics. Each machine

is configured before delivery, tested for many hours in depth, measured at the factory

and run in.

For each basic machine / machine delivered, a measurement and test report with the

customer's order number is kept at the manufacturer isel Germany AG, and can be

requested by you as a buyer. All basic machines / machines are measured with

circularity tester QC20 by Renishaw® in all three interpolation planes or laser

interferometer.

As a prerequisite for your work, you need basic knowledge in CNC technology and PC

application, and if possible, a basic knowledge of the terminology of the currently

applicable Machinery Directive (MRL):

- MRL 2006/42/EC since 29.12.2009 legally binding

Please follow these operating instructions so that you

•can work properly install / start up the CNC basic- / CNC machine

•and work it safely and effectively

•Keep hazards away from people and equipment

•and fully use the performance of the CNC machine.

The statements in these operating instructions are based on a standard scope of

delivery, with which the machine is ready for operation. You can skip statements (e.g.

regarding accessories and software), which do not affect your machine in your initial

study of these operating instructions.

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The statements in these operating instructions apply to the following equipment /

technical level of the CNC machine control:

•all

motor output stages are

fitted with

Standstill monitoring

(from 01/07/2008)

•the operating software used is: ProNC /6/ / Remote /7/ from software version

V1.46.2.1

To install and set up software or the accessories, please also consult the other

manuals and instructions.

These are indicated in the source directory.

Example CNC basic machine ICP 4030:

•(partly completed machine)

•without tool, no clear definition of the intended purpose

•this CNC machine is delivered without a CE mark

•the declaration of incorporation applies to this CNC machine.

Fig 1: ICP 4030 EC CNC basic machine

Example CNC basic machine ICP 4030:

•Complete machine

•fitted with the tool cutter spindle, so suitable for drilling / cutting

•this CNC machine is delivered with a CE mark

•the declaration of conformity applies to this CNC machine.

Fig 2: JCP 4030 EC CNC machine

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2 Intended use, foreseeable misuse

isel-CNC machines / isel-CNC basic machines are CNC controlled machines with

several linear axes or an optional rotating axis. The motor output stages are

controlled via a control core either independently (CNC operation) or PC-based

CNC control (DNC operation). The complete control and power electronics for all

axes is housed behind the back wall of the machine.

Difference between a CNC machine and a CNC basic machine:

isel-CNC machine:

In the Machinery Directive 2006/42/EG legally binding since 29.12.2009, the term

“Machine“ is defined as follows (quote from MD, Article 2, Letter a):

"Machine"

•

an assembly, fitted with or intended to be fitted with a drive system other than directly applied

human or animal effort, consisting of linked parts or components, at least one of which moves,

and which are joined together for a specific application;

Every isel-CNC machine, delivered with a tool (e.g. cutter or engraving spindle,

dosing unit, sensor like CCD camera or triangulation laser, water jet nozzle, plasma

burner or equiv.), is a machine pursuant to the Machinery Directive 2006/42/EC,

because it is manufactured and to be used for a specific purpose or for a specific

application and thus use.

The use results from the type of the tool (fitted on a movable axis), for example:

Tool = machining spindle

Application for cutting, drilling

Tool = engraving spindle

Application for engraving

Tool = dispensing unit

Application for sticking, dispensing

Tool = water jet nozzle

Application for water jet cutting

etc.

As the manufacturer, isel Germany AG can carry out the statutory required risk

assessment for CNC machines. CNC machines are supplied with housing.

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isel-CNC basic machine:

In the new Machinery Directive 2006/42/EC legally binding since 29.12.2009, the

term “partly completed machines“ is defined as follows (quote from MD, Article

2, Letter g):

“partly completed machine“

•

an assembly which is almost machinery but which cannot in itself perform a specific

application. A drive system represents a partly completed machine. Partly completed

machinery is only intended incorporated into or assembled with other machinery or other

partly completed machinery or equipment, thereby forming machinery to which this

Directive applies;

Every isel-CNC basic machine delivered without a tool and therefore not for a

specific application, is partly completed machinery pursuant to the Machinery

Directive 2006/42/EC.

•The CNC machine / CNC basic machine is designed for use in dry rooms

(workshops, labs or similar rooms) and industrial companies (maximum ambient

temperature: 40°C)

•CNC machine:

The CNC machine (complete machine) must be used accordingly based on the type of the

tool fitted on the machine. This means, the concrete tool of the CNC machine determines

the proper use of the machine in accordance with the Machinery Directive (Annex I, Section

1.1.2). Under this premise, the CNC machine is suitable for milling, drilling, cutting,

engraving, dosing, measuring or water jet cutting. The CNC machine is not suitable for

graphite machining.

Suitable processing materials are light metals, plastics, wood, glass, circuit board materials

and the like.

Not permitted are materials that produce harmful gases when they are processed.

The CNC machine is prepared for an extraction device. This extraction is preferably suitable

for dry dust (wood dust, fibreglass / fibreglass-platinum dust and similar).

•The CNC basis machine (partly completed machine) may be supplemented

by you as the buyer of the basic machine with a wide range of suitable

processing tools for the CNC machine (complete machine) in compliance with

the requirements of the Machinery Directive. You are responsible for the CE

certification if you deploy / use or sell (market) the machine. The CE certification

also contains the statutory mandatory marking of the safe machine with the CE

mark.

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•CNC machines for milling:

The CNC cutting machines are designed for cutting / drilling the following materials:

Aluminium, copper, brass, plastics (e.g. GRP/fibre glass), wood

Processing magnesium is prohibited due to the risk of fire.

In the processing of steel / stainless steel only engraving works or processing with low

cutting forces is possible.

Cutters and drills may be used up to a maximum shaft diameter of 7 mm.

In the case of the tools form cutters and counter-bores for the wood sector, the cutting

diameter shall not exceed 45mm and the shank diameter shall not exceed 7mm.

•The rapid traverse rates should, depending on the system size, not exceed the

value of 150 mm / sec to a maximum of 200mm / sec.

•The feed speed of the tools in the material must be determined technologically

and should always be less than the rapid traverse rate.

•The user is responsible for the secure clamping of the tools in the tool holder.

The (reasonably) foreseeable misuse includes the operation of the CNC machine by

two persons. It is prohibited for a person in the test mode (see Section 7.1 Operating

modes) to activate the acknowledgement button on the operating panel and the

other person to reach into the working area of the machine with opened door or

perform activities of any kind therein.

There must be no tampering with the lock of the protective cover (on the back).

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