Isel ICV 4030 EC CNC machine Operating manual

Figure 1: ICV 4030 EC

Assembly manual for CNC base machines

(partly completed machines)

Operating manual for CNC machines

(complete machines)

Type: ICV 4030 EC

isel Germany AG, D-36124 Eichenzell, Bürgermeister-Ebert-Str. 40

+49 6659 981-0 +49 6659 981-776

CNC base machine / CNC machine: Type ICV 4030

Information about this operating manual

Abbreviations

MD Machinery Directive 2006/42/EC

Symbols used in this manual

Various symbols are used in this manual to draw your attention to important information

/ circumstances, and dangers:

Warning!

Warning of dangers which can result in harmful effects on the health, physical injury, or death.

Warning! Life-threatening voltage

Warning of danger from electrical current. Non-observance can result in severe injury or death.

Attention!

This symbol identifies information which must be observed in order to avoid damage or malfunctions.

Information:

This symbol identifies important information and instructions.

Safety information

Before you commission the CNC machine ICV 4030 EC, or work with or add supplements and/or make modifications to the electrical installations of the machine / in the switch cabinet /5/ of the machine, you must carefully read:

x the safety instructions in this operating manual (Section 3) and x the safety instructions for electrical drives and control units in the operating

manual for the positioning module with CANopen interface /1.1/ and/or /1.2/

This operating manual must be kept in the immediate vicinity of the machine and must remain accessible to personnel (operators, fitters, maintenance personnel) at all times.

Assembly manual / operating manual for ICV 4030 EC page 2


Copyright

©

isel Germany AG

, 2015

All rights reserved.

Print errors and mistakes cannot be entirely ruled out despite all care on our part.

We appreciate your assistance with any recommendations for improvement or notification of errors.

CE mark for (complete) CNC machines:

isel CNC machines are CE compliant and marked accordingly.

The CE Declaration of Conformity applies for these machines.

No CE mark for incomplete machines:

Partly completed machines (definition in accordance with the Machinery Directive

2006/42/EC) do not have a CE mark.

The CE Declaration of Conformity applies for these machines.

Commissioning is not permitted for any other machine parts and components to which the CE safety guidelines must be applied until all corresponding requirements have been fulfilled.

The company

isel Germany AG

assumes no warranty or liability if you make modifications on the machine which influence the CE compliance of the machine.

The EMC test only applies for the original configuration of the partly completed machine

/ machine (including switch cabinet), and the CNC control panel as delivered from factory.

Manufacturer: isel Germany AG

Bürgermeister-Ebert-Strasse 40

36124 Eichenzell, Germany

Tel: +49 6659 981-700

Fax: +49 6659 981-776

Email: [email protected] http://www.isel-germany.com

Article number: 970280 BE018

(Translation of the original operating manual)

Revisions Date of change

31/07/2015

Reason for change

First print

Changed by

RL



Table of contents

1 Introduction .............................................................................................................. 6

2 Intended use, foreseeable misuse .......................................................................... 9

3 Safety instructions ................................................................................................. 12

3.1

General safety instructions ..........................................................................12

3.2

Special safety instructions ...........................................................................14

4 Scope of supply / condition as supplies (QS) ..................................................... 17

4.1

Standard scope of supply ............................................................................17

4.2

Condition as supplied ex works (quality assurance) ....................................18

5 Set-up and connection of the CNC machine ......................................................... 20

5.1

Dimensions and spatial requirements .........................................................20

5.2

5.3

5.4

Transport of the CNC machine ....................................................................21

Setup of the CNC machine ..........................................................................21

Protective cover with safety bolt ..................................................................22

5.5

Connection to the AC mains power supply, wiring ......................................22

5.5.1

Connection to the AC mains power supply 23

5.5.2

Connections on the rear side 24

6 Commissioning - CNC technology terminology .................................................. 25

6.1

Controls .......................................................................................................25

6.2

6.3

Coordinate system and workpiece zero point ..............................................25

Assignment of axes of movement ...............................................................26

6.4

6.5

Reference point, machine zero point, and home position ............................26

Workpiece fastening ....................................................................................27

7 Operation ................................................................................................................ 28

7.1

Operating modes .........................................................................................28

7.2

Door locking / door release / standstill monitor ............................................29

7.3

Control PC / controls ...................................................................................30

7.3.1

Control PC: Button for PC on / off 30

7.3.2

7.3.3

7.4

CNC controls - front side

Control PC: USB jack(s)

31

35

Installing and starting CNC software ...........................................................36



7.5

7.5.1

7.5.2

7.5.3

AUTOmatic mode - production on the CNC machine ..................................37

Establishment of a state of readiness for operation

Production: Machining / production of a workpiece

Ending the readiness for operation

38

42

43

8 Accessories ............................................................................................................ 44

9 Technical advice and sales ................................................................................... 45

10 Cleaning, lubrication, and maintenance ............................................................... 46

10.1

Cleaning ......................................................................................................46

10.2

Lubrication ...................................................................................................46

10.2.1

Basic lubrication 46

10.2.2

Re-lubrication 46

10.2.3

Lubrication points of linear axes X, Y, and Z

10.3

47

Maintenance intervals according to operating hours counter ......................49

10.4

Maintenance tasks ......................................................................................50

11 Faults ....................................................................................................................... 51

12 Return of waste electrical and electronic devices for disposal ......................... 53

13 Customer information ............................................................................................ 54

14 Remote diagnosis .................................................................................................. 55

15 Technical data of the CNC machine / CNC base machine .................................. 56

15.1

Clamping surface and travel range..............................................................56

15.2

Technical data .............................................................................................56

16 Declaration of Conformity or Declaration of Incorporation? .............................. 57

16.1

Declaration of Conformity for (complete) machine ......................................58

16.2

Declaration of Incorporation for (partly completed) base machines ............59

17 Exploded view, spare parts lists ........................................................................... 60

17.1

Axis system layout .......................................................................................62

18 List of references ................................................................................................... 69

19 Index ........................................................................................................................ 70



1 Introduction

All isel CNC base machines (as defined in Machinery Directive 2006/42/EC partly

completed machines or partial machines) and/or isel CNC machines (as defined in Machinery Directive 2006/42/EC machines, i.e. complete machines) of the type

ICV 4030 (as well as machines of the type ICP 4030) are tested CNC machines which offer you the full scope of possibilities for two or three dimensional machining of workpieces.

The machines are built and equipped in various sizes and versions. They are based on precisely tailored and variably mounted standard profiles and drive units which are assembled depending on the requirements of the machine type (the so-called machine kinematics). The outer appearance of the machines of the same type is always the same. The applications of the concrete CNC machine corresponding to the mounted tool (on the Z-axis) can be very diverse.

The control and safety concept and the basic layout of the mechanical components are the same for all CNC base machines / CNC machines of the type ICV 4030.

Prior to delivery, each individual machine is configured, thoroughly tested for several hours, measured and started up at the factory.

A measurement and test report is archived by the manufacturer isel Germany AG under the customer order number for each delivered base machine / machine and can be requested by you as the purchaser. All basic machines / machines are tested with QC20 ball-bar testers from Renishaw® in all three interpolation levels and/or laser interferometers.

As a fundamental requirement for your work, you must have basic skills in CNC technology and PC application, and, if possible, basic understanding of the terminology of the currently applicable Machinery Directive (MD):

- MD 2006/42/EC

legally binding since

29/12/2009

Please observe this operating manual in order to

• properly install / commission the CNC base / CNC machine,

• work safely, quickly and efficiently,

• keep dangers away from people and the equipment,

• and to fully utilise the performance capability of the CNC machine.

The versions in this operating manual are based on a standard scope of supply in which the machine is ready for operation. Versions (e.g. accessories and software) which do not pertain to your machine can be skipped over when studying this

operating manual for the first time.



The versions in this operating manual apply for the following equipment / technical status of the CNC machine: x all motor end phases are equipped with standstill monitor (effective

01/07/2008) x used as operating software: ProNC /6/ / Remote /7/ with software version

V1.46.2.1 or higher

Please also observe the additional manuals and instructions for installation and commissioning of software or the accessories.

They are indicated in the list of references.



Example CNC base machine ICV 4030 EC: x partly completed machine x not equipped with tool, no final definition of the purpose of use x this CNC machine is delivered without CE mark

Declaration of Incorporation applies for this CNC machine

Figure 2: ICV 4030 EC CNC base machine

Example CNC machine ICV 4030 EC: x complete machine x equipped with milling spindle tool, thus suitable for drilling / milling x this CNC machine is delivered with CE mark

Declaration of Conformity applies for this CNC machine

Figure 3: ICV 4030 EC CNC machine



2 Intended use, foreseeable misuse

isel CNC machines / isel CNC base machines are CNC-controlled machines with multiple linear axes and/or an optional rotary axis. The motor end phases are controlled by a PC-based CAN-CNC control unit (according to CANopen standard).

The complete control and power electronics for all axes are arranged in the rear wall of the machine.

Difference between a CNC machine and a CNC base machine:

isel CNC machine:

In the legally binding Machinery Directive 2006/42/EC effective as of 29/12/2009, the term 'machine' is defined as follows (excerpt from MD, Article 2, a):

'Machine' x an assembly of linked parts or components, at least one of which moves through some type of

actuator, with associated power and control circuits, joined together for a specific purpose in the processing, treatment;

Every isel CNC machine supplied with a tool (e.g.milling or engraving spindle, dosing device, sensor element, such as a CCD camera or triangulation laser, water jet nozzle, plasma torch, etc.) is a machine in the sense of the Machinery Directive

2006/42/EC, because it is designed for a specific purpose and is therefore

manufactured and used

for an intended purpose

.

The use is determined by the type of tool (mounted on a moving axis), such as:

Tool = machining spindle -> used for milling, drilling

Tool = engraving spindle -> used for engraving

Tool = dosing unit

Tool = water jet nozzle etc.

-> used for adhering, dosing

-> used for water jet cutting

As the manufacturer, isel Germany AG can perform the legally required risk assessment for CNC machines. CNC machines are delivered with an enclosure (all four sides, but open on top).



isel CNC base machine:

In the legally binding Machinery Directive 2006/42/EC effective as of 29/12/2009, the term 'partly completed machine' is defined as follows (excerpt from MD,

Article 2, G):

'partly completed machine' x an assembly which is almost machinery but which cannot

in itself perform a specific application .

A drive system is partly completed machinery. Partly completed machinery is only intended to be 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 base machine that is supplied without a tool and is therefore not provided

for a specific application

is a partly completed machine as defined in the

Machinery Directive 2006/42/EC. x The CNC machine / CNC base machine is designed for use in dry rooms

(workshops, laboratories and/or similar rooms) and industrial operations

(maximum environmental temperature: 40°C). x CNC machine: type of tool mounted on the machine. This means that the concrete tool of the CNC machine defines the intended use of the machine in the sense of the Machinery Directive (Annex I, section 1.1.2). According to this logic, the CNC machine is suitable for milling, drilling, cutting, engraving, dosing, measuring, or water-jet cutting. The CNC machine is not suitable for processing graphite. o Suitable materials to be processed include light metals, plastics, wood, glass, circuit board materials, etc. o Materials which produce gases harmful to the health when processed are not permitted. o The CNC machine is prepared for an extraction device. This extraction is primarily suited for dry dusts (wood dust, GRP / glass fibre circuit board dust, etc.). you as the purchaser of the base machine with the various suitable machining 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 use the machine yourself and/or sell it (put on the market). The

CE certification also includes the statutorily required marking of the machine with the CE mark.


CNC base machine / CNC machine: Type ICV 4030 x CNC machinery for milling: o The CNC milling machinery is intended for the milling / drilling of the following materials:

aluminium, copper, brass, plastics (e.g. GRP/fibreglass), wood o The machining of magnesium is prohibited due to the risk of fire. o Only engraving work or machining with low cutting forces is possible for the machining of steel / stainless steel. o Mills and drills having a shaft diameter greater than 7 mm may not be used. o The form cutter and countersinker tools for wood applications may not have a cutting diameter greater than 45mm or a shaft diameter greater than 7mm. x The rapid motion speeds should not exceed 150mm/sec to 200mm/sec depending on the system size. x The advance speed of the tools in the material must be determined technologically and should always be lower than the rapid motion speed. x The user is responsible for ensuring the safe clamping of the tools in the tool holding fixture.

The (reasonably) foreseeable misuses include operation of the CNC machine by two people. One person pressing the acknowledge button (ACK button) on the control panel (see section 7.1 operating modes) in test mode and the other person reaching into the work area of the machine with the sliding door open during an axis movement or carrying out similar tasks therein is prohibited.

The locking device on the protective cover (on the rear side) may not be manipulated in any way.



3 Safety instructions

Carefully read this section of the operating manual before connecting and commissioning the machine! As with all technical systems, fault-free function and operational safety are only guaranteed with this system if the general safety precautions and special safety instructions are observed for the operation of this machine.

3.1 General safety instructions

1. The setup and commissioning of the machine may only be carried out by authorised personnel with appropriate qualification.

2. The machine may only be used as specified in this manual. The manufacturer accepts no liability for damages which arise with use of the machine for other applications.

3. The CNC machine may only be operated for the machining of suitable materials using tested accessory parts. With the use of unapproved materials and accessory parts (e.g. mills), damage to the machine or workpieces can occur. In this case, the manufacturer excludes all liability.

4. Prior to the commissioning of the machine, ensure that the mains voltage specified on the type plate of the individual components matches the available mains voltage.

An incorrect mains voltage can destroy the machine and its components.

5. To avoid an electric shock, do not introduce any objects into the machine; this does not apply for the intended exchange of parts as specified in this operating manual.

6. Always disconnect the machine from the mains before performing maintenance tasks.

7. Never operate the machine in locations in which there is a danger of water or other liquids penetrating into the control unit behind the rear wall cover or the operating elements on the front side.

8. The supporting surface on which the machine is installed must be sufficiently stable; observe the permissible floor load bearing capacity.

9. Only authorised service technicians are permitted to open the machine housing and perform repairs on the machine.

10. Please observe that there may be a risk of injury with a mill clamped in the milling spindle.

11. The milling machine may only be operated with original accessories or appropriate accessories approved by the manufacturer. Only original parts may be used for the replacement of parts as specified in this operating manual. The manufacturer assumes no liability for damages resulting from the use of accessories or third-party parts which have not been approved.

12. The milling machine may not be installed in explosion-prone areas.

13. When routeing the mains cable, avoid creating trip hazards and causing damage to the cables.

14. If a modification of the CNC Machine or its components is made without the written consent of the manufacturer, the EC Declaration of Conformity will lose its validity.

15. Avoid inhaling the dusts created when cleaning the machine.



16. Only clean the machine with suitable cleansers (standard household, non-abrasive cleansers).

17. Mobile telephones should not be used near the machine. Disruptive influences on the CNC control unit cannot be ruled out.



3.2 Special safety instructions

x The CNC machine surrounded by an enclosure and/or protective cover around the work area.

The clear viewing panes installed in the machine frame and/or the protective cover are provided for the safety of the operating personnel. The panes may not be removed. The material of these panes is:

- PETG = polyethylene terephthalate with glycol or

- polycarbonate, e.g. trade name Makrolon ®

The clear viewing panes guarantee protection from moving machine parts during operating of the machine (during the setup and/or workpiece machining) and from any tool or machine parts ejected from the work area due to a material break. The

CNC machine is open on top, so complete protection from ejected parts is not provided (residual risk).

The enclosure reduces the noise level and retains chips arising during machining.

The protective cover is locked during machining (bolt) and cannot be opened.

This safety device (door lock, the so-called Schmersal switch) may not be removed or altered.

Without a complete, intact housing, including undamaged PETG or polycarbonate panes, a CNC machine supplied with CE mark cannot be commissioned.

x The drilling and/or milling tools used with machining spindle on the CNC

machine may not have a shaft diameter greater than 7 mm (standard) with the

SK11 tool holding fixture. In case of uncertainty or questions about tool selection, please contact the Application Technology department at isel Germany AG. x The CNC base machine without enclosure and/or protective cover is a partly completed machine in the sense of the Machinery Directive 2006/42/EC and is delivered without CE mark. The Declaration of Incorporation and assembly instructions apply.

As owner of the CNC base machine, you are responsible for taking suitable protective measures based on your risk assessment in order to fulfil the safety requirements on the machine in accordance with Machinery Directive

2006/42/EC.

x Always ensure the firm seating of the workpieces. The use of the workpiece clamping device for the concrete machining is the responsibility of the owner of the

CNC machine. Unsuitable, non-secure clamping devices can lead to serious accidents with deadly consequences or physical injury and/or severe damage of the workpiece, the tool, the clamping device, or other machine parts as a result of the loosening of the workpiece from the workpiece clamping device. x There is an Emergency Stop switch on the front side for emergency situations. This switch disconnects the voltage supply of the power electronics (motor end phases) and the frequency converter for the main spindle drive. The shutdown takes place in accordance with Stop Category 1 (controlled shutdown and subsequent disconnection of the energy supply to the drives).


CNC base machine / CNC machine: Type ICV 4030 x Only trained, skilled personnel may use the key switch on the controls, because there is an increased risk of injury in test mode.

Please keep the spare key under lock and key. x Ensure that there is adequate ventilation when there is dust or gas development cause by the machining of the materials. x If the sound pressure level at the machine exceeds the value of 70dB(A), suitable hearing protection must be worn by the operating personnel. x Work on and with the machine may only be carried out by authorised, trained, and instructed personnel. These personnel must have received special instruction in the dangers (special residual risk) which can occur. x The machine must be shut down by pressing the Emergency Stop switch before a tool change takes place. x No flowing water may be used for the cooling; only a cooling device (see accessories) with which a water vapour or air may provide the cooling effect. No drips may form and flow under the clamping plate. x ATTENTION! High leakage current (earth leakage current, protective

conductor current)!

An additional protective conductor must be connected (cross-section, routeing, and terminal in the switch cabinet are described in section 5.5 Connection to the AC

mains power supply) before connection to the AC mains power supply.



High leakage current

ATTENTION! High leakage current (earth leakage current,

protective conductor current) An additional protective conductor must be connected before connection to the AC mains power supply. An

additional protective conductor (cross-section: 2.5 mm

2

or 4 mm

2

, see below) must be connected before connection of the CNC controller to the AC mains power supply! Before electrical commissioning of the machine, an additional protective conductor of 2.5 mm installation) or a protective conductor of 4 mm

2

2

(protected

(unprotected installation) must be permanently connected from the terminal identified on the rear housing wall to the point where the protective conductor has a cross-section of at least 10 mm

2

copper or 16 mm

2

aluminium (e.g. building current distribution board). Please contract a qualified electrician to perform this work. If you use an earth leakage circuit breaker (FI) to safeguard the conductor / limit leakage current: An FI switch with AC characteristics should not be used. With the use of frequency inverters and chopper end phases in the conductor units, overlapping leakage currents with pulsing direct current and direct current can arise in addition to AC leakage currents. Please consult with your qualified electrician.

The term leakage term should be understood as earth leakage current

in this case. This is defined in the standard EN 60204-1:2007 in

section 8.2.8, Comment 1.

If the CNC machine (ideally) is isolated from the earth reference

potential, the earth leakage current is the same as the protective conductor current.



4 Scope of supply / condition as supplies (QS)

4.1 Standard scope of supply

The following are included in the standard scope of supply of the CNC machine / CHC base machine: x Machine housing with three linear axes including x Complete x Drilling and milling machine with 3 mm collet x Key for collet, AF 22 x Clamping set (hand lever, stop rails, 5 mm Allen key) x Triangle key for unlocking the cover switch x Mains supply cable, PC - machine connection cable x 4-way power strip with illuminated main switch x ProNC or RemoteWin as software (optional) x CAD/CAM software isy-CAM (optional) x Machine documentation with documentation parts: o CNC base machine / CNC machine operating manual o Operating manuals for System module SKM-E, iSM10, or iSM5, motor end phase iMD10/20/40, iPC series control computer o Circuit diagrams / parts lists

The control software ProNC /6/ or

Remote /7/ including CAN CNC Motion Control software is completely installed on the control PC (integrated in the CNC control panel or in the switch cabinet). The CNC machine is tested with this software. The Declaration of Conformity for CNC machines is only valid if the CNC machine is used with this control software

(ProNC version 1.45.6.1 or higher or Remote version 1.45.6.1 or higher). The control software ProNC / Remote is archived on CD-

ROM and USB memory stick for the purpose of re-installation

(setup) as a backup. The user is responsible for archiving user programs on the supplied USB memory stick.

Please refer to the delivery note for the exact scope of supply of your CNC machine.



4.2 Condition as supplied ex works (quality assurance)

The Renishaw® QC20 ballbar system is used for verification / testing of the machine precision of the CNC machines.

The precision of the axes of all produced CNC machines / CNC base machines can be determined with this system prior to delivery. This verification / testing is a basic component of the proof of machine capability in accordance with DIN ISO 230: x DIN ISO 230-2: Determination of the positioning uncertainty and the repeat accuracy of the positioning of numerically controlled axes. This testing takes place on request and for testing purposes with laser interferometer XL80. x DIN ISO 230-4: Circularity testing for numerically controlled machine tools. This testing takes place on every machine with a QC20 ballbar system.

QC20 ballbar system

The QC20 can be mounted on any machine tool and requires only a few minutes.

The circular measurement is controlled by means of a simple, standardised CNC program. The data is recorded and evaluated in the diagnostic software and the errors are show with their respective sizes and influence on the overall precision in graphic/tabular form.

The shapes of the recorded circles (on all three interpolation levels XY/XZ/YZ) provide information about possible machine errors:

x Contouring error

/ position tolerance error perpendicularity in / backlash x Quadrant transition

/ circular error

The measurements take place with a radius of 50mm, 100mm, 150mm, and 300mm, depending on the size of the axes to be measured. In the process, the shortest axis should always be considered.

Delivery of each CNC machine only takes place when all parameters are within the required range. The results of the measurements are saved and archived on a machine and/or order basis.

Figure 4: Circularity measurement with the Renishaw QC10 circularity measuring system

Assembly manual / operating manual for

ICV 4030 EC page 18


The laser interferometer Renishaw XL-80 is used for measurement / testing of positioning accuracy. This laser measuring system enables both the complete testing of complex machine tools and/or automation systems / special machines and simple positioning units / axes of movement.

There are comprehensive options available for static and dynamic testing with the available lenses, such as determination of the real speed profile v=v(t) of a linear axis and thus verification of the permanence of this expressive signal progression:

Acceleration over time

Speed over time

Figure 5: Speed profile of a linear axis with torque limitation

The position measurement is the measurement that is most frequently performed on the machine. The laser measuring system measures the positioning accuracy and the repeat accuracy with a comparison of the position indicated by the machine with the actual position measured by the laser measuring system.


ICV 4030 EC page 19


5 Set-up and connection of the CNC machine

5.1 Dimensions and spatial requirements

The spatial requirements of the machine are limited to the outer dimensions and adequate space around the machine in order to be able to operate and equip it. A clearance of approximately 10 cm is required behind the machine for the plug. Ensure a sufficient clearance of 30 cm on the sides in order to ensure proper function of the fans.

The cover of the housing opens upwards such that the overall height is approximately

1.35 metres.

Figure 6: Dimensions and spatial requirements

Always keep the triangle key separate from the machine - particularly during transport.


ICV 4030 EC page 20


When setting up your machine, only use suitable, safe clamping tools (refer to 'Accessories').

Always ensure the firm seating of the workpieces.

When planning the installation area for the CNC machine, access on all sides for trained personnel during maintenance and service tasks must

be ensured!

5.2 Transport of the CNC machine

Remove the transport locks. Only use suitable lifting equipment (forklift, lift truck). Only lift the machine from below.

If transporting the machine at a later time, please ensure that the mains and connection cables are not damaged.

Always pull out the mains plug before transport.

Ensure that the machine is not subjected to heavy jolting or vibration during transport. Always keep the triangle key for manually unlocking the door separate from the machine.

5.3 Setup of the CNC machine

The mounting surface / machining surface on the CNC machine and all axes are precisely aligned perpendicularly at the factory.

Never disconnect the fasteners of axes or the mounting bracket on which the transverse axis (X-axis) is mounted. Otherwise, the machine must be measured again by a technician from the manufacturer, isel Germany AG.

Position the machine on a level and stable surface. The height-adjustable feet can be used to compensate for unevenness in the floor / on the table.

A spirit level with a precision of at least 0.1 mm/m is required for the precise alignment of the machine.

Secure the height of the machine feet with the lock nuts.


ICV 4030 EC page 21


We offer the following on-site service for secure setup of your new CNC machine:

CNC base machine / CNC machine measurement / adjustment with laser interferometer on the customer's / end user's premises

(Article number: 991300 0001).

5.4 Protective cover with safety bolt

For compact CNC machines of the type ICP, the enclosure is uniform, which means it cannot be removed.

The clear viewing panes (material: polycarbonate) installed in the machine frame and/or the cover guarantee protection from moving machine parts during operating of the machine (during the setup and/or workpiece machining) and from any tool or machine parts ejected from the work area due to a tool or workpiece break.

Without a complete, intact housing, including undamaged polycarbonate panes, a CNC machine supplied with CE mark cannot be commissioned.

5.5 Connection to the AC mains power supply, wiring

In order to reach the connections of the servo motor control unit, please proceed as follows:

Switch off the machine and pull out the mains plug!

Remove the protective cover of the machine by unscrewing the hexagon screws and disconnecting the earthing cable from the protective cover.

Now you can connect additional components to the connections of the servo motor control unit (e.g. frequency converter, solenoid valves, sensors, actuators, etc.).

Figure 7: Opening the housing of the servo motor control unit


ICV 4030 EC page 22


5.5.1 Connection to the AC mains power supply

The CNC machine is controlled by a control PC /3/ and power electronics for the motors

(motor end phases /1.1/ /1.2/). The complete power control unit - integrated behind the rear machine wall /5/ - is completely wired and connected to the machine.

An extensive overview of the wiring of the electrical / electronic components is provided in the machine documentation /5/.

Do not connect the AC mains cable of the machine control unit until the machine is ready for commissioning. The following specifications must be observed:

High leakage current

ATTENTION: High leakage current!

Connect an additional protective conductor (cross-section: 2.5 mm

2

or 4 mm

2

, see below) before connection of the CNC machine to the AC mains power supply!

Before electrical commissioning of the machine, an additional protective conductor of

2.5 mm

2

(protected installation) or a protective conductor of 4 mm

2

(unprotected installation) must be permanently connected from the terminal identified on the rear side of the machine to the point where the protective conductor has a cross-section of at least 10 mm

2

copper or 16 mm

2

aluminium (e.g. building current distribution board). Please contract a qualified electrician to perform this work.

Connection to the AC mains power supply: TN-S mains, i.e.

-

Single-phase connection: PHASE (P), NEUTRA CONDUCTOR, PROTECTIVE

CONDUCTOR

-

Conductor P (L1) 16A - C or gGgL

If you use an earth leakage circuit breaker (FI) to safeguard the conductor / limit leakage current: An FI switch with AC characteristics should not be used. With the use of frequency inverters and chopper end phases in the power units (switch cabinet) of our CNC machines, overlapping leakage currents with pulsing direct current and direct current can arise in addition to

AC leakage currents. Please consult with your qualified electrician.

The term leakage term should be understood as earth leakage current in this case.

This is defined in the standard EN 60204-1:2007 in section 8.2.8,

Comment 1.

If the CNC machine (ideally) is isolated from the earth reference potential, the earth leakage current is the same as the protective conductor current.


ICV 4030 EC page 23

5.5.2 Connections on the rear side


Number Identification

1

2

3

4

5

6

7

8

LAN

USB 3.0

Recovery

Description

RJ45 connection jack for LAN connection to the iPC 25

USB 3.0 jack for external periphery (mouse or keyboard)

USB 2.0 jack for recovery of the iPC 25 and external periphery (mouse or keyboard)

VGA connection

Earthing pin

Mains connection socket with main switch and fuses

15-pin connection jack for VGA monitor

M4 connection pin for additional potential equalisation

230V AC mains adapter connection with main switch and mains fuse 2 x 10A; IEC 127

HBC

Schuko plug socket

Additional mains connection socket with main switch and fuses I

Only replace defective fuses with original spare parts!

L/N/PE mains connection socket wired in accordance with IEC CEE7/3

(optional auxiliary equipment)

230V AC mains adapter connection with main switch and mains fuse 2 x 10A slow; IEC

127 HBC for optional auxiliary equipment. Attention! No shut-off in case of

Emergency Stop

Only replace defective fuses with original spare parts!


ICV 4030 EC page 24


6 Commissioning - CNC technology terminology

6.1 Controls

The following image provides an overview of the controls on the CNC control panel.

All controls and their functions are described in detail in section 7.3.

Figure 8: Controls

6.2 Coordinate system and workpiece zero point

The coordinate system of the CNC machine is a right-handed coordinate system, as shown in the figure.

The workpiece zero point P0 can be defined with the CNC software (e.g. via teach-in) or is freely programmable in the user program.

Yellow stickers on the axes of the CNC machine identify both the axes (X, Y, or Z are normally axis address letters for linear axes; A, B, or C are normally axis address letters for rotational axes) and the positive / negative axis direction for linear axes and/or the positive / negative rotational direction for rotary axes.

Figure 9: Coordinate system of linear axes

If you have to change the arrangement of the coordinates, please read the motor end phase manual /1.1/ /1.2/. If you have any questions, please contact our technical support.


ICV 4030 EC page 25


6.3 Assignment of axes of movement

The assignment of the positive direction of movement of the linear axes of movement in relation to the operating positions is as follows:

X-axis = transverse axis -> +X to the right; -X to the left

Y-axis = longitudinal axis -> +Y away from the operator; -Y towards the operator

Z-axes = vertical axis Z -> +Z upwards; -Z downwards

The logical address letters are as follows:

X

= End phase node address 1

Y-axis = longitudinal axis = Y = End phase node address 2

Z-axis = vertical axis Z = Z = End phase node address 3

A-axis = rotary axis = A = End phase node address 4

6.4 Reference point, machine zero point, and home position

The reference point of the machine

(machine zero point) is defined in the factory in the axis position x x x rear (Y-axis) left (X-axis) top (Z-axis)

The reference point is defined by a hardware limit switch (factory setting).

The home position was signalled to the control unit by means of an electromagnetic switch contact in older isel Germany AG machines (in systems without standstill monitoring in the motor end phases).

Figure 10:

Home position sensor

The home position sensor is no longer necessary for isel machines due to the equipment of the motor end phases with standstill monitoring.


ICV 4030 EC page 26


6.5 Workpiece fastening

When setting up your CNC machine, only use suitable, safe clamping tools (refer to 'Accessories').

Always ensure the firm seating of the workpieces.

For this purpose, use the optional clamping set from isel Germany AG.

The clamping set comprises a hand lever clamping device and two stop rails with fastening material for the Tslot plate.

Always ensure the firm seating

of the workpieces.


ICV 4030 EC page 27


7 Operation

7.1 Operating modes x Operation mode AUTO = AUTOMATIC operation = machining mode

In the AUTO operating mode, you can run a selected (i.e. open) user program (ISO /

PAL / NCP or CNC file) on your CNC machine to machine your workpieces. The door is locked during the machining process (no axis standstill).

In this operating mode, you can only open the door after all axes of the CNC machine are no longer in movement (standstill monitor) and the machining spindle (e.g. milling spindle motor in CNC milling machines) is no longer rotating (speed = 0 rpm), and is therefore also switched off.

Press the COVER button to open the door.

After closing the door, the safety bolt is automatically locked again.

x Operating mode TEST = SETUP mode = test mode

For testing and control purposes, you can run the (selected) user program (ISO / PAL /

NCP or CNC file) on the CNC machine with an open door if you turn the key in the key

switch to the TEST position to the right (SETUP mode = test mode). The program now continues for as long as the ACK button (acknowledgement button) is held.

Test mode has no influence on the advance and/or rapid speed of the axes. The current speed is not changed.

Releasing the ACK button (with door sill open) will switch off the power end phases.

The activation of the machining spindle (e.g. milling spindle motor) by the safety circuit module (SC module) is suppressed in test mode.

Attention: Risk of injury!

The key switch = operating mode selector switch may only be used by qualified and authorised personnel, because there is no protection from moving machine axes after the door has been opened in test mode.


ICV 4030 EC page 28


7.2 Door locking / door release / standstill monitor

The locking of the (single) door is a basic safety-related function.

A special home position is not monitored by the control unit and thus has no

influence on the door locking / door

release.

Instead, the standstill monitor integrated in all motor end phases is relevant.

This standstill monitor has a redundant design in compliance with DIN EN 62061

A home position sensor not provided because there is standstill monitoring of all axes!

(VDE 0113-50) (cross-circuiting detection).

All motor end phases integrated in the machine control unit /5/ of the CNC machine

(e.g. IMD10 /1.1/ or IMD20 /1.2) are connected in series for safety purposes and forward the cycle signals if the servo motor controlled by the corresponding end phase does not move outside of a (positional) rule window). The cycle signals generated by the safety module (e.g. 'sent') are also received and evaluated by this module. With a standstill of all servo motors / axes, the door is released in AUTOMATIC mode.

Basically, the linear axes X, Y, and Z of the CNC machine and all optional rotary axes

A, B, or C must be at a 'standstill' in order to be able to open the door when the key

switch is set to AUTO (AUTOMATIC operating mode).

Key switch = operating mode selector switch

In the SETUP operating mode (key switch = operating mode selector switch set to

TEST position), the door can always be opened regardless of the current position /

standstill of the linear axes X, Y, and Z, as well as all optional rotary axes A, B, or C of the CNC machine.

Operating manual for ICV 4030 CAN page 29


The door control (as a component of the safety circuit module (SCM), controls the sensor / actuator (safety bolt) for the door locking: x Sensor function of the safety bolt:

1. Door closed

2. Door locked x Actuator function of the safety bolt:

Manual door unlocking:

For special situations (e.g. safety bolt defect or mains voltage failure or machine / system is not connected to the mains power supply), you can manually unlock the door locking mechanism with the triangular

key (in the accessories kit accompanying the CNC machine).

1. Switch off the machine.

2. Turn the triangular key - without applying excessive force - a half rotation to the left and open the door.

You may not operate the

machine in this state.

Current does not flow to the motors of the CNC machine in this state.

3. Turn the triangular key back to the right.

You may not operate the machine

if the safety bolt is manually unlocked.

7.3 Control PC / controls

7.3.1 Control PC: Button for PC on / off

After you have switched on the main switch on the rear side of the machine, you can start the control

PC, i.e. boot the Windows operating system. To do so, press the button located on the front side of the machine.



7.3.2 CNC controls - front side

Operation of the CNC machine takes place with the controls on the front side of the machine.

Figure 11: Detail: Standard machine controls

Figure 12: Detail: Special application machine controls

Number Identification Description

13 Main switch of the machine

Main switch for switching the voltage supply ON and OFF

Switch for accessories Switch for activating the mains connection socket on the rear side 14



Controls for the machine control unit

Number Identification Description

1

2

3

4

5

6

7

8

Emergency OFF button Shut-off of the voltage supply of the motor end phases and the working spindle.

Power ON button The voltage supply of the end phases is connected.

Fault indicator

Start button

Stop button

Cover button

ACK (Acknowledge) button

Operating mode selector switch

The fault indicator signals an error in the safety circuit.

Starts the processing of the current NC program or resumes an interrupted process.

Interrupts the processing of the current NC program. Pressing the Stop button again ends the processing (does not apply for all control unit configurations).

This button is used to open the cover (if present). The cover can only be opened if the Cover button is illuminated. This is the case if the axes are in the HOME position or the operating mode selector switch is in the Test mode position.

This button must be pressed in order to be able to move the axes in test mode with the cover open.

This key switch is used to switch between automatic and setup modes. The cover and/or door can only be opened in automatic mode if the axes are in the home position. In setup mode, the cover can be opened and the axes can be moved when the ACK button is pressed.

Controls for the control computer

Number Identification

9

10

11

12

Power button

Power LED

HDD LED

USB slots

Description

Switching on the integrated control computer

Operating indicator of the control computer

Indicator for hard disk access

USB 2.0 slots for USB devices (USB stick, WIBU, etc.)



1 Emergency STOP button switches off the operating voltage of the motor end phases / drive control unit and the frequency converter of the working spindle when pressed (controlled shutdown,

STOP Category 1 in accordance with EN 60204-1). Press the Emergency STOP button in the event of danger to your health or the machine safety. The safety module

(safety module) in the switch cabinet is designed for Category 3 in accordance with

DIN EN ISO 13849-1. The Emergency STOP button is unlocked by turning it to the right.

The mains input voltage in the control cabinet is still present after an Emergency STOP button is pressed. Only the operating voltage

(DC or AC) for the motor end phases and/or spindle motor inverter is interrupted.

signals an error in the safety circuit module (SC module). The motor end phases and the inverter for the working spindle are not released.

3 Power ON button

switches on the operating voltage of the motor end phases / power electronics. The operating voltage of the motor end phases can only be switched on if the Emergency

STOP button is unlocked.

The operating manual for the safety circuit module /2/, you will find information about possible causes if the operating voltage cannot be switched on in the chapter Status dialogue.

4 Start button

starts the user program or resumes a suspended movement and/or a suspended user program. The machine movement moves to the exact place where it was when interrupted by the Stop button if the machining was not ended, i.e. cancelled, by the software.

5 Stop button

stops the running user program and thus immediately stops any axis movement of the machine axes. The current program line in the user program remains marked /6/ /7/.

The machine remains switched on, the door can be unlocked when all machine axes are at a standstill (by pressing the COVER button), and thus opening is released.

Pressing the Stop button again cancels the processing of the user program.


CNC base machine / CNC machine: Type ICV 4030 deactivates the safety locking mechanism and thereby enables the opening of the door when pressed, insofar as all necessary conditions of the SC module are fulfilled. The button is only functional when the light is illuminated.

7 ACK button, ACKnowledge button

must be pressed and held in setup mode (TEST operating mode) to move the axes while the door is open. If you release the button while the door is open, the safety circuit module (SC module) switches off the drive control unit (power unit).

8 Key switch = operating mode selector switch

You can change between x

AUTO (AUTOMATIC operation = machining mode) or x

TEST (SETUP mode = test mode) operating modes with the key switch.

In which operating mode can the machining spindle (milling spindle) be switched on?

Operation mode AUTO = AUTOMATIC operation = machining mode:

The machining spindle can only be switched on and operated at the setpoint speed if the door is closed. You can only open the door in automatic mode if all machine axes are at a standstill (standstill monitoring), regardless of the programmed speed of travel

(advance).

Operating mode TEST = SETUP mode = test mode:

Basically, the machining spindle cannot be switched on in setup mode. You can always open the door in setup mode, regardless of the current speed of travel

(advance) of the machine axes. In order to prevent an Emergency STOP as a result of the opening of the door in this operating mode, press the acknowledge button (ACK

button) on the control panel.

AUTO ▬▬► TEST operating mode selection:

When changing the operating mode from AUTO ▬▬► TEST during workpiece machining, the machining spindle runs down (with spindle inverter with a release input) and/or is switched off.

TEST ▬▬► AUTO operating mode selection:

With the resetting from TEST ▬▬► AUTO, the machining spindle is run up again (to the previous setpoint speed) and/or is switched on.



Changing operating modes is only permitted when the movement axes of the CNC machine are in the

STOP state!

If the operating mode change does not take place when the movement axes are in the stop state, the machining spindle

or the workpiece can be damaged.

Attention: Risk of injury !

The key switch = operating mode selector switch may only be used by qualified and authorised personnel, because there is no protection from moving machine axes after the door has been opened in test mode.

7.3.3 Control PC: USB jack(s)

The USB jacks are provided for connection of USB devices (USB memory stick, WIBU USB dongle for

ProNC or external CD-ROM drive).

The NC data exchange between user and control PC /3/ takes place via this interface. You can transfer NC programs or drawings created on an external computer to the control PC with a USB memory stick and then perform the workpiece machining with these NC programs.

USB

The control PC is already wired at the factory and integrated into the machine control unit /5/. As a user, you do not normally need to make any changes to the wiring. The connections for USB, LAN and the monitor are already guided 'outwards' to the front or rear panel.

If you would like to execute an ISO or PAL user program with the

ProNC /6/ programming software, you must use the WIBU USB dongle. Plug the dongle into the USB port.

No WIBU USB dongle is required to execute ISO or NCP programs with Remote /7/.



7.4 Installing and starting CNC software

You can choose between the CNC user interfaces / CNC operating software x Operating and programming software

ProNC x Operating and output software (interpreter)

Remote.

The CNC software included in the scope of supply of your CNC machine x ProNC including Remote Article number: Z11-333500 or x Remote

Article number: Z12-334500 includes the appropriate manuals x ProNC:

Operating manual and programming rules

manual saved in PDF format on the correspondingly identified installation CD and the supplied

USB memory stick.

Also use the USB memory stick for the archiving of your user programs.

In the condition of the CNC machine as supplied, the CNC operating software ProNC or

Remote (depending on the order / scope of supply) is already completely installed.

In case of uncertainty regarding the installation (e.g. a software update) of ProNC or the configuration of the software modules, please read the ProNC operating manual chapter

3.4.4 'Configuration dialogue' /6/.

In case of uncertainty regarding the installation (e.g. a software update) of Remote or the configuration of the software modules, please read the REMOTE operating manual chapter 2.8.3.1 'Configuration dialogue' /7/.

For further information about the CNC operating software, please refer to the respective manuals and/or ReadMe files on the installation CD.

Alternatively, you can also start the installation assistant.

This assistant will guide you through the installation.



- by clicking on the icon on the desktop or in the task bar or

- by clicking in the start menu folder CNCWorkbench

7.5 AUTOmatic mode - production on the CNC machine

The production of parts on a CNC machine is performed according to the following sequence:

1: Establishment of a state of readiness for operation (production preparation)

2: Production: Machining / production of one or multiple workpieces

3: Ending of the state of readiness for operation (cleaning or maintenance)

The following description is simplified (i.e. without manual or automatic tool change) and only applies for the production of one milled part with the Remote CNC operating software.



7.5.1 Establishment of a state of readiness for operation

Steps:

1: Start the Remote CNC operating software, close the cover of the CNC machine

2: Move the operating mode selector switch to AUTO

3: Press the Power ON button on the CNC control panel

Result (the background image with isel logo and text is monochromatic by default):

4: Reset of the movement control -> all drive units are initialised and their readiness for operation is established



5: Execute a reference run of all axes (standard setting: the Z-axis is referenced first)

-> after this step, the numerical axes can be moved manually

6: Manually move the axes to a position in which the tool can clamped in the clamping fixture of the machining spindle; open the cover; clamp the tool; clamp the workpiece blank on the machining surface; close the cover; determine the workpiece zero point, e.g. via teach-in:

7: Open the machining program (here: the NCP file isel.ncp):



Result (text view):



Result (graphic view):

8: Reference the Z-axis for safety purposes:



Steps:

1: Adjust the processing mode to automatic:

2: Press the START button on the CNC control panel -> Machining starts

Result (text view):



3: Wait until the machining has ended; when the workpiece has been completely machined, the axes of the CNC machine (Z-axis first, then the X and Y axes) automatically move to park position when the following output settings (Settings ->

Output of the CNC file):

4: Open the cover, then unclamp and inspect the machined workpiece

7.5.3 Ending the readiness for operation

Steps:

1: Press the EMERGENCY STOP button for safety purposes -> All drives are deenergised.

2: If necessary, carry out cleaning tasks (see section 9).

3: Close the Remote CNC operating software (File -> Exit).

4: On the CNC control panel, click on Shut down or press the PC ON/OFF button on the right side of the CNC control panel.

5: Switch the main switch on the control cabinet to the 'OFF' position.



8 Accessories

The following accessories matching the ICP 3020 / 4030 can be ordered: x Clamp set (clamping lever SH1, SH2, 2 stop rails, Allen key) x Additional collets for the respective milling spindles x Mill, drill, graver tool set x Linear tool changer with high-frequency spindle, option: length measuring sensor x Rotary axis (4th axis) x Main spindle drives iSA 500, 750, 900 x Machining spindle UFM 500, UFM 1050 x Vacuum clamping system isel Vakufit x Cooling air system isel CoolMin: cooling device with cold air nozzle (down to -20°C) x Working chamber lighting x CAD/CAM software isyCAD/CAM 2.5

Note for compressed air connection of accessories:

In order to be able to use the optional vacuum clamping system, the cold air nozzle, or the tool changer and the collet of the machining spindle, a compressed air connection must be available in the installation location of the machine.

Accessories

Air pressure Air consumption

Pneumatic vacuum pump 4 - 6 bar 100-150 l/min (1 nozzle)

Cold air nozzle

Tool changer cover

3 - 10 bar

3 - 6 bar

100-150 l/min

Pulse

Milling spindle with automatic tool change > 7.5 bar Pulse

Pivoting unit mounted on the milling spindle for extraction

(especially for wood processing)

2 bar Pulse

The software necessary for the tool change, including the tool length measurement is a component of the Remote / ProNC operating and programming software.

Ensure that all accessories are correctly mounted and observe the applicable standards and safety regulations.



9 Technical advice and sales

For further information and/or orders, please contact

Technical advice and sales

Jürgen Balzer

Christian Bley

+49 (0) 6659 / 981-774 [email protected]

+49 (0) 36964 / 84-516 [email protected]

Steffan Gärth

Stefan Koch

Fax:

+49 (0) 6659 / 981-773

+49 (0) 36964 / 84-526 [email protected] [email protected]

+49 (0) 6659 / 981-776

Also visit our home page: www.isel-germany.de

or request the current catalogue.

Sign up for our email newsletter for information about current products and innovations.

You can also visit our permanent display at our headquarters in our factory in Eichenzell,

Germany on all work days and see all of our products on display at all the important trade fairs.

We provide a sampling of our product range in our showroom and offer you practical demonstrations when possible.



10 Cleaning, lubrication, and maintenance

Switch the main switch off before any cleaning or maintenance tasks and pull out the mains plug in order to prevent inadvertently switching on the machine.

10.1 Cleaning

x Regularly remove all chips from the machine with a hand brush or vacuum (no compressed air). This protects the mechanical components from premature wear. x The sealing lips contain a Teflon component and do not require any special maintenance. x Clean the plastic discs with a non-abrasive plastic cleanser.

10.2 Lubrication

x The guide bars and drive shafts are provided with long-life central lubrication at the factory. The guides and drive shafts should be re-lubricated every 500-1000 operating hours depending on the work load. For this purpose, use the grease press and corresponding special grease available as accessory items for central lubrication. x Do not lubricate too much at once; the shafts and steel rails do not have to be swimming in grease. x If you want to lubricate the machine, first perform a reference run, then open the cover, then switch on the machine.

10.2.1 Basic lubrication

The drive components are pre-lubricated at the factory with isel special grease. They are ready for operation.

The EC Safety Data Sheet in accordance with Directive 93/112/EEC and 11014-1 can be requested from the factory.

10.2.2 Re-lubrication

Only use isel special grease for re-lubrication of linear bearings with shafts.

Use the following article numbers to order the necessary grease: x 299032 0002 Grease cartridge x 299032 0003 Grease press

Depending on the usage situation, re-lubrication must take place every 500 to 1000 operating hours.

For lubrication of the X-axis, slide the carriage to the left*, remove the plastic plug on the left side of the machine, and lubricate through the now visible lubricating nipple. You can access the guide rails again through the sealing lips.

Grease properties:

The isel special grease is distinguished by the following properties: x extreme wear reduction


CNC base machine / CNC machine: Type ICV 4030 x significantly lower consumption x miscible with lithium and calcium greases x water-repellent x highly resistance to cold, heat, salt water, and solvents x temperature range: -25°C to 200°C x emergency running >300°C x service life extension of up to 6 times x extremely good adhesion to metal surfaces

Classification and identification according to EU Directives 67/548/EEC and

88/369/EEC - Water hazard class 1.

10.2.3 Lubrication points of linear axes X, Y, and Z

In order to lubricate the Y-axis, you must first slide the T - slot plate all the way forward* and then unscrew it from the Y-axis (six screws).

Remove the plastic plug underneath it and lubricate through the now visible lubricating nipple. You can access the guide rails through the sealing lips.

In order to remove the cover plate of the Y-axis, unscrew the fastening screws.

S

Identifies access points to all lubrication points in all drawings.



Figure 13: Lubrication points of X, Y, and Z axes

For lubrication of the X-axis, slide the carriage to the left*, remove the plastic plug on the left side of the machine, and lubricate through the now visible lubricating nipple.

You can access the guide rails again through the sealing lips.

On the Z-axis you must first remove the processing machine from its mount, remove the three plugs, and push the carriage all the way down. *

You can add some oil to the guide rails through the two lateral holes.

The lubricating nipple for the drive is now positioned behind the opening.

*

If the machine is switched off, you can slide the carriage by hand.



10.3 Maintenance intervals according to operating hours counter

The software operating hours counter integrated in the isel control software ProNC /6/ or Remote /7/ notifies the operating personnel about the lapse of the current maintenance interval:

Green bar: Minimum maintenance interval elapsed

Red bar: Maintenance interval elapsed; maintenance work is due

Clicking on the icon provides further information:

The maintenance interval is pre-set at the factory to a value of 300 machining hours.

If, when starting up the isel control software ProNC or Remote, the notice


CNC base machine / CNC machine: Type ICV 4030 that maintenance is required is displayed, the following maintenance tasks must be carried out.

10.4 Maintenance tasks

The following tasks must be performed after the laps of a maintenance interval: x Visual inspection lubrication film on the ball screw spindle and steel shaft guide through the sealing lips of linear axes X, Y, and Z x Re-lubrication, if necessary (see section 'Lubrication points') x Visual vacuum and clean as necessary opening, vacuum and clean as necessary

Further maintenance tasks include: as necessary: Cleaning dirt out of the interior

Acoustic check for development of unusual noises

2 months: Visual inspection of linear units - wear

Visual inspection of toothed belt deflections in the Z-axis for tension and wear

1 year: Replacement of toothed belts in the Z-axis

Check for freedom from play of the linear guides and ball-type linear drives

(circularity test on all levels with Renishaw measurement)

Toothed belts in the Z-axis

: refer to the parts list of the linear units in chapter

17.1 Axis layout



11 Faults

Error Cause

Mains connection not provided

Solution

Check the power circuit

Mains plug, power strip

The system does not start up

Main switch not switched on Switch on the main switch

The POWER button does not work

Software does not work correctly

Drive motor of an axis does not react

Defective fuse

At least one motor end phase signals an error

Emergency STOP not unlocked

Defective fuse

System not switched on

Pull out the mains plug

Replace the fuse

Diagnose and eliminate the cause of the error

Unlock the Emergency

STOP

Pull out the mains plug

Replace the fuse

Switch on the system (main switch)

End phase not switched on

CAN connection not correct

No voltage supply of the end phase, fuse defect

Switch on the end phase

(POWER button)

Check cable connections,

CAN node addresses, and terminating resistance

Check the fuses in the switch cabinet /5/ and/or the power end phase /1.1/ or

/1.2/

Temperature protection of the end phase is active

- Check fan in the switch cabinet

- Check / clean filter in the fan

Replace end phase (send in to manufacturer)

End phase defect

Connection plug has disconnected

Cable break

Check plug - at the control output and at the motor

Replace cable



Error

Machine (spindle) does not work, i.e. it cannot be switched on

Red LED on the frequency converter blinking

Cause

Not released by the SC module

Mains switch on the Kress machining spindle switched off

Incorrect signalling parameter (spindle start) setting

Operating mode selector switch set to TEST

Door locking open

Solution

Check spindle release signal

Switch on the mains switch on the Kress machining spindle

Check and correct the signalling parameter

Move the operating mode selector switch to AUTO

Set the door switch to automatic unlocking

Error on the speed-controlled frequency converter

Check frequency converter parameter settings

Overcurrent / overvoltage Check the frequency converter parameter settings against the motor data of the working spindle



12 Return of waste electrical and electronic devices for disposal

Collection

Users of electrical and electronic devices are obligated, in accordance with the countryspecific regulations, to separate disposal of the waste equipment. Waste electrical and electronic equipment may not be disposed of with household waste. The separate collection required for recycling and re-use, whereby natural resources can be conserved.

Return and collection systems

Disposal of your Gantry OverHead M CNC machine, particularly the electronic components, may not take place with household waste. Local waste disposal companies have made the necessary disposal facilities available for this purpose.

Meaning of symbols

All electrical and electronic equipment identified with this symbol must not be disposed of with household waste in accordance with EU Directives.



No one is authorised to disclose information differing from the specifications in this manual.

Guarantee

The manufacturer, isel Germany AG, guarantees that this product is free from material and manufacturing defects. isel Germany AG DOES NOT ASSUME ANY FURTHER

LIABILITY OR ANY IMPLICIT GUARANTEE WITH RESPECT TO SALABILITY OR

SUITABILITY FOR A SPECIFIC PURPOSE. The user is responsible for the use and intended use of the product. If damage to the product occurs during the warranty period, you only claim and the only obligation of isel Germany AG is the repair or the replacement of the product.

Limitation of liability

Insofar as a limitation of liability is legally permissible, there is no liability whatsoever for the manufacturer, isel Germany AG, for losses or damage caused by this product. This applies regardless of whether this involves direct, indirect, special, ancillary or consequential damages, regardless of the legal basis, including guarantee, contract, negligence, or intent.

The General Terms and Conditions (GTC) of isel Germany AG apply.



Please contact our service department about remote diagnosis via the world wide web

(internet):

Frank Hecht

Frank Jansen

+49 (0) 6659 / 981-763

+49 (0) 6659 / 981-765 [email protected]

[email protected]

The latest version of TeamViewer ® is used as a communication tool for the remote diagnosis.

Connection of the control PC /3/ in the CNC control panel of your CNC machine / CNC base machine to the internet is required for online remote diagnosis. Every control PC is equipped with an Ethernet connection for this purpose.

The connection is established via the internet in three steps:

1. Step: Contact our support by telephone or email and request advice. The operator at the CNC machine becomes a participant, the isel service technician acts as advisor.

2. The participants starts the Windows program 'TeamViewerQS_de.exe' on the control

PC.

This program can be found under the following directory:

C:\CNCWorkbench\Tools\TeamViewer

The reports the following:

After connection has been successfully established, the remote diagnosis can begin.



15 Technical data of the CNC machine / CNC base machine

15.1 Clamping surface and travel range

Model Width in mm

Depth in mm

Height in mm

Clamping surface

(W x D) in mm

Paths of travel

X / Y / Z in mm

Z clear height in mm

ICV 4030 EC 769 834.5 1342.5

15.2 Technical data

Technical data

T - slot grid

Weight approx.

Sound pressure level

Mains connection

Drive motor

Main drive spindle

Fuse

Earthing

Air humidity

Environmental temperature

Installation location

Storage [°C]

700 x 375 400/ 300 /140

-10 to 50

Up to 2000 m above sea level

200

ICV 4030 CAN

Operation [°C]

[mm] 25

[kg] 150

[dB(A)] <75

230V, 50/60Hz, external fuse max.

16A

156 watts each

Type-dependent

Mains input 2 x 10A slow HBC

Corresponding to Protection class 1 max. 80%

5 to 40



16 Declaration of Conformity or Declaration of Incorporation?

In the new legally binding Machinery Directive 2006/42/EC effective as of 29/12/2009, the term

'machine'

is defined as follows (excerpt from Machinery Directive 2006/42/EC

Article 2 a):

'Machine' x an assembly of linked parts or components, at least one of which moves through

some type of actuator, with associated power and control circuits, joined together for a specific purpose in the processing, treatment;

For all isel CNC machines which are delivered with a tool (e.g.milling or engraving spindle, dosing device, sensor element, such as a CCD camera or triangulation laser, water jet nozzle, plasma torch, etc.), the Declaration of Conformity in this operating manual applies.

These CNC machines are to be used

for the purpose of the intended application

based on the type of tool (mounted on the moving axis):

Tool = machining spindle -> used for milling, drilling

Tool = engraving spindle

Tool = dosing unit etc.

-> used for engraving

-> used for adhering, dosing

In the Machinery Directive 98/37/EC valid as of 28/12/2009, the term 'partial machine /

partly completed machine' and/or the term 'partly completed machine' in the new

Machinery Directive 2006/42/EC, which is legally binding as of 29/12/2009, is defined as follows (excerpt from Machinery Directive 2006/42/EC, Article 2, g):

'partly completed machine' x an assembly which is almost machinery but which

cannot in itself perform a specific application . A drive system is partly completed machinery. Partly completed machinery is only intended to be incorporated into or assembled with other machinery or other partly completed machinery or equipment, thereby forming machinery to which this Directive applies;

The Declaration of Incorporation in this operating manual applies for all isel CNC base

machines which are delivered without a tool (e.g. milling or engraving spindle, dosing device, sensor element, such as a CCD camera or triangulation laser, water jet nozzle, plasma torch, etc.), and therefore not

for an intended use

.



16.1 Declaration of Conformity for (complete) machine

Declaration of Conformity in accordance with EC Machinery Directive 2006/42/EC,

Annex II A

The manufacturer isel Germany AG


36124 Eichenzell, Germany hereby declares that the following product

Product name:

Types:

Type plate:

isel CNC machine ICV 4030

ICV 4030 EC Art. no.: 280260 XXXX

conforms to the requirements of the Directive identified above, including the applicable amendments at the time of the declaration.

The following harmonised standards have been applied:

EN ISO 12100:2010

EN ISO 13857:2008

EN ISO 349:1993

EN ISO 953:2009

EN ISO 13850:2008

EN 14121-1:2007

EN 60204-1:2006

Safety of Machinery - Safety of machinery -- General principles for design --

Risk assessment and risk reduction

Safety of machinery -- Safety distances to prevent hazard zones being reached by upper and lower limbs

Safety of machinery. Minimum gaps to avoid crushing of parts of the human body

Safety of machinery. Guards. General requirements for the design and construction of fixed and movable guards

Safety of machinery -- Emergency stop -- Principles for design

Safety of machinery. Risk assessment. Part 1: Principles

Safety of machinery. Electrical equipment of machines - Part 1: General requirements

The following additional EU Directives which are relevant for this product were applied:

EMC Directive 2004/108/EC

Low Voltage Directive 2006/95/EC

The technical documentation for this machine has been compiled in accordance with Annex VII, Part A.

The manufacturer is obligated to electronic submission of this technical documentation to the national competent authorities upon request.

Person authorised to compile the technical documentation: Helmut Danz

Place, date: Dermbach, 31 July 2015

____________________________

Werner Kister, Chair



16.2 Declaration of Incorporation for (partly completed) base machines

Declaration of Incorporation in accordance with EC Machinery Directive 2006/42/EC,

Annex II B

The manufacturer isel Germany AG


36124 Eichenzell, Germany hereby declares that the product

Product name:

Types:

isel base machine ICV 4030

ICV 4030 EC Art. no.: 280260 XXXX

Type plate: conforms to the basic safety and health requirements of EC Machinery Directive 2006/42/EC Annex I.

The following additional EU Directives which are relevant for this product were applied:

EMC Directive

Low Voltage Directive

2004/108/EC

2006/95/EC

The following harmonised standards have been applied:

EN 349:2008-09

EN ISO 12100-1:2003

EN ISO 12100-2:2003

Safety of machinery. Minimum gaps to avoid crushing of parts of the human body

Safety of machinery -- Basic concepts, general principles for design

– Part 1:

Basic terminology, methodology

Safety of machinery -- Basic concepts, general principles for design

– Part 2:

Technical principles

Safety of machinery -- Emergency stop -- Principles for design

Safety of machinery. Risk assessment. Part 1: Principles

EN ISO 13850:2008

EN 14121-1:2007

EN 60204-1:2006 Safety of machinery. Electrical equipment of machines - Part 1: General requirements

The technical documentation for this machine has been compiled in accordance with Annex VII, Part B.

The manufacturer is obligated to electronic submission of this technical documentation to the national competent authorities upon request.

Person authorised to compile the technical documentation: Helmut Danz

The product (partially completed machine) is intended for incorporation into a machine or combination with other partially completed machinery to form a machine in the sense of Machinery Directive 2006/42/EC,

Article 1, Section (1), Letter a.

The commissioning of the compete machine (product) is prohibited until the machine into which this product has been incorporated or of which it is a component complies with the provisions of all relevant directives (particularly Machinery Directive 2006/42/EC) and this (complete) machine has been provided with a CE mark.

Place, date: Dermbach, 31 July 2015

____________________________

Werner Kister, Chair



17 Exploded view, spare parts lists

Figure 14: Exploded view ICV 4030, DZ8000


CNC special machine apt type FlatCom L

Parts list

Pos. no.

1

Item number

680670 8001

2

3

680620 1001

680630 1001

31

32

33

34

27

28

29

30

35

36

37

38

19

20

21

22

23

24

25

26

7

8

9

10

11

4

5

6

680670 8025

680670 8034

680670 80241

680670 8051

675012 6559

680650 8065

680670 8044

680670 8053

12

13

14

15

680670 8054

680640 1001

680670 8063

680670 8289

16

17

639112 29775

564028 1000

18 219200 1000/219201

559071

610019 0002

569056 2000

610019

891201 0081

891201 0101

891122 0301

891124 0081

891124 0141

891124 0161

891124 0301

891594 0102

891181 0101

891592 0082

891131 0061

891134 0161

893160 0001

893050 0001

893054 0001

892022 0001

Quantity

4

10

12

5

6

2

9

1

2

1

3

12

1

2

1

2

2

22

2

19

4

4

6

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

Name

Chassis ICV-EC

ICV 4030 - EC sheet metal machine X-axis

ICV 4030 - EC sheet metal machine Y-axis

ICV 4030 - EC sheet metal machine X-axis cover

ICV 4030 - EC sheet metal machine Y-axis cover

ICV 4030 - EC front panel with controls

ICV 4030 - EC connection panel

LED - machine lighting - PW45 for ICV

Control unit IMD20 - installation - ICV 4030 - EC

Central lubrication counter presser

ICV 4030 - EC rear wall cover

Table plate PT 25 ICV 4030 - EC

ICV 4030 - EC sheet metal machine Z-axis

ICV 4030 - EC X-axis connecting plate

ICV 4030 - EC Y-axis service panel

Double flange ø80-ø50-2

Aubomatcon - filter fan ZL 803 - 120x120 - with fan

Energy chain 1

4-way plug strip (6.3 mm)

Blind plug ø16

Cable duct 650 mm lg

Blind plug ø9.5

Raised countersunk screw DIN 966 4.8 VZ M 3 x 8


Cylinder screw DIN 6912 8.8 M 4 x 30





Raised countersunk screw DIN 7380 M 6 x 10


Raised countersunk screw DIN 7380 M 4 x 8

Countersunk screw DIN 7991 M 3 x 6

Countersunk screw DIN 7991 M 6 x 16

Serrated washer DIN 6797 Ø3.2

Washer DIN 125 ST 3,2


Hexagon screw DIN 934 8 M 3

DZ2977

Drawing no.

DZ8001

DZ8036

DZ8035

DZ8025

DZ8034

DZ8024

DZ8051

DZ6559

DZ8065

DZ8044

DZ8053

DZ8054

DZ8060

DZ8063

DZ8289



17.1 Axis system layout

X-axis



24

25

26

27

21

22

23

29

11

16

17

18

19

12

13

14

15

Parts list

Pos. no.

1

2

3

4

Item number

680524 1250

680524 1328

675012 3730

675012 7255

Quantity

2

1

1

1

Name

Shuttle H22.5 ICP 20-15,30-20,40-30

ICP X-axis bearing

Motor plate EC-60 LES21

Shuttle for limit switch GOH - Z-axis

ICV X-Y-axis - limit switch mounting bracket

ICV X-Y-axis - clamping block round nut

ICV X-axis lubricant distributor

8050 1 -

622002 0001 2 Pin M8x0.75x10mm with taper (replaces TP0150-4)

613110 0001

211135 10562

613502

680000 0647

623071 0151

398723 0007

840003 0028

840003 0027

3

3

2

1

2

2

1

1

Ball screw nut - 16x10

Ball screw spindle - 16x10 - L=562

Ball screw nut wiper

ELF 1 with face end hole - L=648

Shaft carriage WS6 - L=150

EC60 - 48V servo module - ICV-EC - X-Y-axis

Threaded union - 90 degrees -M6-4

Threaded union - straight QSM-M6-4

218002 8012

420010

642523

397011 1012

397015 1012

891374 0061

891168 0101

891122 0121

1

4

1

1

1

2

2

Shaft coupling WK 30-40 D 8 - 12

Flange bearing for ball screw spindle

Flange bearing combination spacer bush D12d6.75

Limit position switch with roller lever - 2pin - L=550


Threaded pin DIN 913 M 6 x 6

Countersunk screw DIN 963 4.8 VG M 2 x 10

6 Cylinder screw DIN 6912 8.8 M 4 x 12

33

37

39

40

891124 0801

893050 1000

893089 4000

893164 0001

2 Cylinder screw DIN 6912 8.8 M 6 x 80

4 Washer DIN 125 ST 2,2

3

2



Operating manual for ICV 4030 CAN

Drawing no.

DZ1250

DZ1328

DZ3730

DZ7255

DZ8039

DZ8040

DZ8046

DZ8048

DZ8049

DZ8050

TE1409

TE2456

TE2859

TP0104 page 63


Pos. no.

42

43

44

Y-axis

Item number

890257 0011

609011 0125

609011 0625

Quantity

1

4

2

Name

Nut DIN 981 M10x0.75

Threaded inserts M6 10x4 125 long

Threaded inserts M6 1cx4 625 long

Drawing no.

TE0162


24

25

26

27

20

21

22

23

14

15

16

17

18

19

28

29

30

31

32


Parts list

Pos. no.

1

2

3

4

Item number

680534 1244

680524 1328

675012 3730

675012 7255

Quantity

2

1

1

1

Name

Shuttle H22.5 ICP 30-20

ICP X-axis bearing

Motor plate EC-60 LES21

Shuttle for limit switch GOH - Z-axis

ICV X-Y-axis - limit switch mounting bracket

8042 1 4030 - EC Y-axis lubricant distributor plate

8043 1 4030

8046 1 4030

8047 2 -

622002 0001

613110 0001

2

1

Pin M8x0.75x10mm with taper (replaces TP0150-4)

Ball screw nut - 16x10

211135 10462

613502

680060 0826

623071 0151

398723 0007

840003 0028

840003 0027

623080 0001

582009

420010

642523

218002 8012

397011 1012

397015 1012

891374 0061

891168 0101

891191 0101

1

2

2

2

1

2

3

4

5

2

2

1

1

1

1

4

8

Ball screw spindle - 16x10 - L=462

Ball screw nut wiper

Guide LFS-12-11 L=542

Shaft carriage WS6 - L=150

EC60 - 48V servo module - ICV-EC - X-Y-axis

Threaded union - 90 degrees -M6-4

Threaded union - straight QSM-M6-4

Lubricating nipple for carriage

Holder for cable tie

Flange bearing for ball screw spindle

Flange bearing combination spacer bush D12d6.75

Shaft coupling WK 30-40 D 8 - 12



Threaded pin DIN 913 M 6 x 6


Countersunk screw DIN 965 4.8 VZ M 3 x 10

Operating manual for ICV 4030 CAN

TE2859

TP0104

Drawing no.

DZ1244

DZ1328

DZ3730

DZ7255

DZ8037

DZ8038

DZ8039

DZ8040

DZ8041

DZ8042

DZ8043

DZ8046

DZ8047

TE1409

TE2456 page 65

Pos. no.


Item number Quantity Name

49

50

51

52

45

46

47

893050 1000

893050 0001

893051 0001

893089 4000

893160 0001

893163 0001

893164 0001

4

6

6




3

6

2

2





56

57

58

890257 0011

609011 0125

609011 0525

1

4

2




Drawing no.

TE0162


Z-axis


Parts list

Pos. no.

Item number Quantity Name

3

4

632505

693001

2

4

TE0275 - Cover profile SK593 P10_4

TE0398 - End edge for sealing lip

5 635001 1 -

6 616002 1 TE0562 - Toothed belt pulley Z25 AT5 for collet D=8mm

7 623065 0001 1 TE1972 - Lock nut for ball spindle nut ø16

TE2342 - Direct drive and life counter bearings side end

2000 1 plate

Drawing no.

DZ2521

TE0174

TE0275

TE0398

TE0561

TE0562

TE1972

TE2056

TE2342


37

38

39

33

34

35

41

42

26

27

29

30

31

Pos. no.

10

13

14

15

19

21


Item number

635014

613105 0001

610110 2471

623072 0013

Quantity

1

1

1

3

Name

TE2328 - Limit switch run-over plate

TE2457 - Ball screw nut - 16x5mm

TE2471 - Dummy plate for protective cover 225x75x80

TE2796 - Shaft slide WS5 - L=70 without ball screw nut

TE2816 - Rubber bonded metal parabolic screw - Art.

2816 1 no.632126 2816

623065 0102 1 TE2935 - Flange for belt drive (LF4-6)

TE5925 - IGP 2520 - LES4 belt drive - end plate - limit switch

1002 1 plate

632126 2374 1 DZ2374 - Rubber bonded metal parabolic screw d12

680670 8062

680670 8429

674501 07901

616001 0002

610110 3745

474156 1048

616400

898122 2131

397030 1012

397015 1012

610016

891168 0101

891190 0061

1

1

1

1

4

1

1

1

1

1

4

4

2

DZ8062 - Z-axis - connecting plate - ICV 4030 - EC

DZ8429 - E-chain holding plate Z-axis -ICV 4030 - EC

SZ0790 - Motor adapter plate

SZ2789 - Toothed belt pulley Z25 AT5 D=11mm

SZ3745 - Micro-switch mounting plate

TP0104 wiper

Servo drive module with EC60, 156W with brake

Tension pulley for toothed belt LF4-LF5

Clamping bush 12-22-13 (Mädler; 615712 00)

Limit switch L=400mm

Limit switch L=950mm

Kapsto cover GPN 300 F-Type 300


Countersunk screw DIN 965 4.8 VZ M 2.5 x 6

TE2951

DZ2374

DZ2513

DZ2518

DZ2519

DZ8061

DZ8062

DZ8429

SZ0789

SZ0790

SZ2789

SZ3745

TP0104

Drawing no.

TE2328

TE2337

TE2435

TE2457

TE2471

TE2796

TE2797

TE2816

TE2859

TE2935

TE5925



53

54

893307 0000

890257 0011

1

1

Washer DIN 988 ST 10 x 1


TE0162

56 890303 0002 1 Square nut M4 - factory standard 10x10x3

*) wear part, annual replacement recommended

18 List of references

/1.1/ Positioning module IMD10 with CANopen interface operating manual:

Manual for motor end phase UVE8112 / IMD10 for brush-type DC servo motors and commissioning program DCSetup.exe; isel Germany AG, 06/2008

/1.2/ Positioning module IMD20 with CANopen interface operating manual:

Manual for motor end phase IMD20 for brushless DC servo motors and commissioning program ACSetup.exe; isel Germany AG, 06/2008

/2/ Operating manual for isel system module SKM-E:

Manual for system module ISKM-E; isel Germany AG, 05/2008

/3/ Operating manual for isel control computer iPC-25:

Manual for control computer (control PC ) iPC-25; isel Germany AG, 06/2014

/4/ CNC control panel operating manual:

Operating manual for the CNC control panel; isel Germany AG, 06/2014

/5/ Circuit diagrams for switch cabinet with isel CAN-CNC control unit):

Circuit diagrams and parts lists for the switch cabinet with IMD20, IMD40, SKME,

CAN I/O, CT inverter isel Germany AG, 09/2015

/6/

ProNC: Operating manual and programming rules:

Manuals (parts 1 and 2) for ProNC operating and programming interface; isel-automation 06/2005

/7/ Remote: Operating and output program for ISO, NCP, and CNC files:

Manual for Remote user interface; isel-automation 06/2005

/8/ EC Machinery Directive 2006/42/EC (legally-binding since 29/12/2009)



19 Index

A

Accessories ............................................................................................................................................................................................. 7

ACK button ........................................................................................................................................................................................... 34

Acknowledge button............................................................................................................................................................................ 34

Assignment of the positive direction of movement ............................................................................................................................. 26

B

Basic lubrication ................................................................................................................................................................................... 46

C

CAN-CNC control unit ............................................................................................................................................................................. 9

CE certification ..................................................................................................................................................................................... 10

CE conformity ......................................................................................................................................................................................... 3

CE mark................................................................................................................................................................................................. 10

Central lubrication ................................................................................................................................................................................ 46

CNC base machine ............................................................................................................................................................................... 10

CNC machine .......................................................................................................................................................................................... 9

CNC machine measurement ................................................................................................................................................................ 22

Compressed air connection .................................................................................................................................................................. 44

Contouring error ................................................................................................................................................................................... 18

Control software .................................................................................................................................................................................. 17

Controls ................................................................................................................................................................................................ 25

Coordinate system ................................................................................................................................................................................ 25

COVER button ....................................................................................................................................................................................... 34

Cover locking ........................................................................................................................................................................................ 29

Cross-circuiting detection ..................................................................................................................................................................... 29

D

Declaration of Conformity ................................................................................................................................................................... 17

Delivery note ........................................................................................................................................................................................ 17

DIN EN 62061 ....................................................................................................................................................................................... 29

DIN ISO 230........................................................................................................................................................................................... 18

Door locking ......................................................................................................................................................................................... 14

E

Earth leakage current .......................................................................................................................................................................... 23

Environmental temperature ................................................................................................................................................................. 10

Extraction device .................................................................................................................................................................................. 10

G

Grease properties ................................................................................................................................................................................ 46

GTC ....................................................................................................................................................................................................... 54

Guarantee ............................................................................................................................................................................................ 54



I

Intended use ......................................................................................................................................................................................... 10

Interpolation levels .............................................................................................................................................................................. 18

isel CoolMin .......................................................................................................................................................................................... 44

K

Key switch ...................................................................................................................................................................................... 28, 29

L

Laser interferometers ............................................................................................................................................................................. 6

Leakage current ................................................................................................................................................................................... 15

Limitation of liability ............................................................................................................................................................................. 54

M

Machine kinematics ................................................................................................................................................................................ 6

Machine zero point .............................................................................................................................................................................. 26

Machinery Directive ............................................................................................................................................................................... 6

Machining surface ................................................................................................................................................................................ 21

MD 2006/42/EC ................................................................................................................................................................................ 6, 69

Mounting surface ................................................................................................................................................................................. 21

O

Operating hours counter ...................................................................................................................................................................... 49

Operating mode ................................................................................................................................................................................... 34

Operating mode selection ................................................................................................................................................................... 34

P

Positioning accuracy ............................................................................................................................................................................. 19

Proof of machine capability .................................................................................................................................................................. 18

Protective conductor current ........................................................................................................................................................ 15, 23

Q

QC20 ballbar system ............................................................................................................................................................................ 18

R

Re-lubrication ....................................................................................................................................................................................... 46

Remote diagnosis ................................................................................................................................................................................. 55

Repeat accuracy ................................................................................................................................................................................... 19

Residual risk .......................................................................................................................................................................................... 14

Right-handed coordinate system ......................................................................................................................................................... 25

S

Safety bolt ...................................................................................................................................................................................... 28, 30



Safety Circuit Module ........................................................................................................................................................................... 30

Safety concept ........................................................................................................................................................................................ 6

SC module ............................................................................................................................................................................................. 28

Schmersal switch .................................................................................................................................................................................. 14

SCM ...................................................................................................................................................................................................... 30

Service .................................................................................................................................................................................................. 22

Software update ................................................................................................................................................................................... 36

Software version .................................................................................................................................................................................... 7

Special grease ....................................................................................................................................................................................... 46

Standard scope of supply ..................................................................................................................................................................... 17

Standstill monitor ............................................................................................................................................................................. 7, 29

Suitable materials to be processed ...................................................................................................................................................... 10

T

TeamViewer ......................................................................................................................................................................................... 55

Tool changer ......................................................................................................................................................................................... 44

Transport locks ..................................................................................................................................................................................... 21

Triangle key for manual unlocking ...................................................................................................................................................... 21

V

Vacuum clamping system ..................................................................................................................................................................... 44

VDE 0113-50 ......................................................................................................................................................................................... 29

Visual inspection ................................................................................................................................................................................... 50

W

Water hazard class ............................................................................................................................................................................... 47


Isel ICV 4030 EC CNC machine Operating manual

Assistant Bot

Assembly manual for CNC base machines

(partly completed machines)

Operating manual for CNC machines

(complete machines)

Information about this operating manual

Abbreviations

Symbols used in this manual

Information:

Safety information

Copyright

isel Germany AG

CE mark for (complete) CNC machines:

No CE mark for incomplete machines:

isel Germany AG

Manufacturer: isel Germany AG

Table of contents

1 Introduction

2 Intended use, foreseeable misuse

3 Safety instructions

3.1 General safety instructions

3.2 Special safety instructions

4 Scope of supply / condition as supplies (QS)

4.1 Standard scope of supply

4.2 Condition as supplied ex works (quality assurance)

5 Set-up and connection of the CNC machine

5.1 Dimensions and spatial requirements

Always ensure the firm seating of the workpieces.

5.2 Transport of the CNC machine

5.3 Setup of the CNC machine

5.4 Protective cover with safety bolt

5.5 Connection to the AC mains power supply, wiring

5.5.1 Connection to the AC mains power supply

6 Commissioning - CNC technology terminology

6.1 Controls

6.2 Coordinate system and workpiece zero point

6.3 Assignment of axes of movement

X

6.4 Reference point, machine zero point, and home position

The home position sensor is no longer necessary for isel machines due to the equipment of the motor end phases with standstill monitoring.

6.5 Workpiece fastening

7 Operation

7.1 Operating modes x Operation mode AUTO = AUTOMATIC operation = machining mode

x Operating mode TEST = SETUP mode = test mode

7.2 Door locking / door release / standstill monitor

7.3 Control PC / controls

AUTO ▬▬► TEST operating mode selection:

TEST ▬▬► AUTO operating mode selection:

Changing operating modes is only permitted when the movement axes of the CNC machine are in the

STOP state!

Attention: Risk of injury !

7.4 Installing and starting CNC software

7.5 AUTOmatic mode - production on the CNC machine

8 Accessories

9 Technical advice and sales

10 Cleaning, lubrication, and maintenance

10.1 Cleaning

10.2 Lubrication

10.3 Maintenance intervals according to operating hours counter

10.4 Maintenance tasks

11 Faults

12 Return of waste electrical and electronic devices for disposal

Collection

Return and collection systems

Meaning of symbols

Guarantee

Limitation of liability

15 Technical data of the CNC machine / CNC base machine

15.1 Clamping surface and travel range

15.2 Technical data

16 Declaration of Conformity or Declaration of Incorporation?

'machine'

16.1 Declaration of Conformity for (complete) machine

16.2 Declaration of Incorporation for (partly completed) base machines

17 Exploded view, spare parts lists

17.1 Axis system layout

18 List of references

19 Index

Key Features