Isel FlatCom L 150 Instructions Manual Download

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isel Germany AG Bürgermeister-Ebert-Straße 40 D-36124 Eichenzell Tel.: (06659) 981-0 Fax: -776

FlatCom, Series M

Assembly Instruction for CNC base machinery

(partly completed machinery)

Operating Instruction for CNC machinery

(complete machinery)

Type: FlatCom ®

Series M (20, 30, 40, 50)

Series L (150, 250, 300)

Series XL (102, 142)

FlatCom, Series L

FlatCom, Series XL

Summary of Contents for FlatCom L 150

Page 1: ...659 981 0 Fax 776 FlatCom Series M Assembly Instruction for CNC base machinery partly completed machinery Operating Instruction for CNC machinery complete machinery Type FlatCom Series M 20 30 40 50 Series L 150 250 300 Series XL 102 142 FlatCom Series L FlatCom Series XL ...

Page 2: ... important notes Ignoring this symbol leads to damages and malfunctions of the machinery Information This symbol indicates important information and notes Observe the safety instructions Before you put into operation the CNC machine CNC base machine FlatCom work with the machine or make additions or changes to with the wiring of the machines electrical control cabinet in the housing of the machine...

Page 3: ... section B is valid For all other machinery parts and components be applied to the CE safety directives initial operation are prohibited until all appropriate requirements are met The company isel Germany AG assumes no responsibility or liability if you make any changes without the consent of the manufacturer of the machine that affect the CE conformity of the machine The EMC test is valid only fo...

Page 4: ...tive measures at CNC base machinery 19 5 5 Cabling and compressed air connection 20 6 Initial operation 21 6 1 Preliminary 21 6 1 1 Operating elements 21 6 1 2 Coordinate system and work piece zero point 21 6 1 3 Assignment of the motion axes 22 6 1 4 Reference point machine zero point and home position 22 6 1 5 Work piece mounting resp clamping 23 6 1 6 Portal machinery CNC machinery of type Euro...

Page 5: ... the Z axis 40 10 Faults 41 11 Remote diagnosis 43 12 Technical Data of CNC Machine CNC Base machine 44 12 1 Clamping area and traversing range FlatCom Series M 44 12 2 Clamping area and traversing range FlatCom Series L 45 12 3 Clamping area and traversing range FlatCom Series XL 46 12 4 Mechanical values electrical values 48 12 5 Sound pressure level 48 13 Declaration of Conformity or Declaratio...

Page 6: ...nder the special order number at the manufacturer isel Germany AG The customer can request this protocol All CNC base machinery CNC machinery are surveyed with circle form tester QC10 from Renishaw in all three interpolation planes resp Laser interferometer As presupposition for your work you need basic knowledges in CNC technics and PC application It would be good to know also the terminology of ...

Page 7: ...ithout tool no clearly definition of application purpose this CNC base machine is delivered without CE mark for this CNC base machine the Declaration of Incorporation is valid Example CNC machine FlatCom 40 complete machine equipped with tool milling spindle so applicable for milling or drilling this CNC machine is delivered with CE mark for this CNC machine the Declaration of Conformity is valid ...

Page 8: ...lling tool engraving tool usage for engraving tool metering device usage for metering tool water jet nozzle usage for water jet cutting The manufacturer isel Germany AG is able to effect a legal prescribed risk assessment for the CNC machines CNC machines will be delivered with a machinery enclosure isel CNC base machine In the new at 29 12 2009 legally binding machine directive 2006 42 EC is the ...

Page 9: ...eel stainless steel only engraving or a processing with low cutting forces is possible o It shall not be used milling spindles with a toolholder greater than ISO 25 or HSK 25 hollow shank taper The speed of the spindle drive may not be higher than the corresponding processing speed for the material o All machines are designed for milling spindles spindle machining induction motor with a maximum of...

Page 10: ...sible for implementation of suitable protection actions as result of your risk assessment Those actions have to comply with all safety requests of MD 2006 42 EU Be always careful that work pieces are tightly clamped The use of save and suitable parts devices for work piece clamping is one of the tasks of the operator Unsave or not suitable devices for work piece clamping can cause unfasten of work...

Page 11: ...persons Those persons have to be informed by a special instruction about possibly appearing endangerments especially residual risk Flowing water must not be used for cooling For cooling purpose only special cooling equipment refer to the chapter accessory may be used This cooling equipment has to generate water fog or an air flow for cooling effect No drops of cooling medium may appear or flow und...

Page 12: ...ontroller CAN PC or Industry PC o System module ISM10 Safety module CAN I O module 24 VDC power supply Machinery documentation with the following parts o This Assembly instruction for CNC base machinery Operating instruction for CNC machinery o Operating instruction for system module ISM10 Servo motor power amplifiers iMD10 IMD20 or IMD40 PC based CNC Controller iSR20 or iSR30 and CNC control pane...

Page 13: ...aluated in the diagnostic software and the errors with their size and the corresponding impact on the overall accuracy are shown in graphical tabular form The form of recognized circles in all three interpolation planes XY XZ YZ provides guidance on any existing machine error tracking error position tolerance straightness error perpendicularity measure error backlash quadrant transitional circular...

Page 14: ...s With the available lenses extensive opportunities for static and dynamic tests are available e g the identification of the real velocity profile v v t of a linear axis and thus the proof of the continuity of meaningful signal curve picture velocity profile of a linear axis with jerk limitation The position measurement is the most commonly performed measurement on a machine The laser measuring sy...

Page 15: ...abinet and the CNC control panel as well as enough space in front or side of the machine to operate it and to be able to set up The two part sliding door of the machine hood important for FlatCom series M only opens as downward as upward so you need additional space above the machine The space requirements for FlatCom Series L and XL are shown in the drawings in section 12 2 Series L resp 12 3 Ser...

Page 16: ...or FlatCom Series M L and XL page 16 Space requirement FlatCom 40 Space requirement FlatCom 50 When planning the space requirement for the FlatCom CNC machinery the ingress for instructed persons in the phase of maintenance and service has to be regarded Operating position Operating position ...

Page 17: ...from the frame feeds Use only appropriate lifting equipment fork lift trucks see picture Lift the machine only from below and do not pull up on the cover In case of a later transfer please make sure that the net cable and connection cables are not damaged Unplug the power supply cable before each transport Take care during transport that the machine is not suspended to heavy vibrations Keep the tr...

Page 18: ... by a technician from manufacturer isel Germany AG Place the machine on a plane and solid area You can compensate the unevenness of the floor table with the adjustable feet For precise alignment of the machine you need a spirit level with an accuracy of at least 0 1 mm m Save the height of the machine feet with the lock nut For safe installation of your new CNC machine on site we offer the followi...

Page 19: ...chine into operation if the enclosure is not complete intact or the polycarbonate resp PETG panes are damaged 5 4 2 Mounting of suitable protective measures at CNC base machinery The delivered CNC base machinery without safety door hood resp without in the machine frame fixed transparent panes are partly completed machinery for the purpose of the directive 2006 42 EC They are delivered without a C...

Page 20: ...ne documentation 5 The mains plug of the control cabinet is to be plugged first if the machine is ready for initial operation accessories air pressure air consumption pneumatic vacuum pump 4 6 bar 100 150 l min 1 nozzle cold air nozzle 3 10 bar 100 150 l min cover of the tool changer 3 6 bar impulse milling spindle with automatic tool change 7 5 bar impulse on the milling spindle mounted swivel un...

Page 21: ...he CNC machine is set as a right system as shown in the picture The work piece zero point P0 can be defined by the software e g via teach in or is freely programmed in the application program A yellow label on each axis marks both the axes X Y or Z as axis letter for linear axes A B or C as axis letter for rotation axis as well as the positive negative axis direction of linear axis resp positive n...

Page 22: ... operator Z axis lift axis Z up Z down 6 1 4 Reference point machine zero point and home position The Reference point of the machine identically to the machine zero point is ex factory at the following axes positions At the back Y axis left X axis at the top Z axis The reference point is set by the hardware limit switches factory set Former FlatCom machines had a home position sensor to signal thi...

Page 23: ... Y axis with the moveable machine table clamping plate for the work piece So a Y motion of the work piece related to the tools top in positive Y direction Y happens toward to the operator 6 1 7 Flatbed machinery CNC machinery of type FlatCom or OverHead A flatbed machine has the following characteristic The clamping plate for the work piece is mounted tightly on the machine frame The work piece is...

Page 24: ...T turn the key in the key switch on the operator panel to right i e to position TEST In operation mode TEST you can process a selected i e opened application program ISO PAL NCP or CNC file on your CNC machine even when the door cover is open but with the following two restrictions 1st restriction When the door cover is open the application program is processed as long as the ACK button ACKnowledg...

Page 25: ...st from the Safety Circuit Module the last to the Safety Circuit Module when the amplifier recognizes that the driven servo motor is not outside a position feed back controlled limit The Safety Circuit Module generates i e transmits two clock signals over two outputs and receives monitors those two clock signals on two inputs When standstill of all servo motors machine axes in AUTOMATIC mode the c...

Page 26: ...tion of safety interlock Cover lock How to do cover unlock manually For special cases e g door lock defect or loss of power supply voltage of the machine you can use the triangular key enclosure of the CNC machine to open the door cover lock manually 1 Switch off the machine 2 Turn the triangular key without using great force a half turn to the left and open the door The servo motors of the machin...

Page 27: ... you can boot the Windows operating system of your Control PC inside the control cabinet Push the button on the right side of CNC operating panel to boot or shut down 6 4 2 CNC operating panel front side operating elements The operation of the CNC machine takes place using the buttons on the external hand control unit or optionally via the buttons on the CNC operating panel 4 the keyboard the mous...

Page 28: ...he control cabinet is switched on Emergency stop button is pulled out Note 2 there chapter 4 1 4 Dialog for Status request If power supply voltage is successfully switched on the power button is lighted green 4 Start button If you press the start button the currently selected opened application program ISO PAL CNC or NCP format is started or a stopped motion of the machinery axes or the applicatio...

Page 29: ...utton when the door cover is open causes an EMERGENCY STOP and therewith a switch off the power voltage supply for the motor power amplifiers and for the frequency converter s driving the working spindle s 8 Mode selection switch key switch Use this switch to change between AUTO processing mode and TEST setup mode In AUTO you can open the cover or safety door of the machine only if no axis is in m...

Page 30: ...ing mode alternation TEST AUTO Operating mode alternation TEST AUTO causes rev up the working spindle to previous target rpm resp the working spindle is switched on Operating mode alternation is permitted only in STOP state of the CNC machinery axes If operating mode alternates not in STOP state of the CNC machinery axes this can damage the working spindle or the work piece Attention Risk of injur...

Page 31: ...the WIBU USB dongle for ProNC 6 or an external CD DVD drive This is the interface to transfer any NC data like NCP ISO PAL or CNC application programs or drawings from for a CAD CAM system from the users Desktop PC to the Control PC 3 If you want to execute an ISO or PAL application program with ProNC 6 a so called WIBU USB dongle has to be plugged to one of the two USB connectors For the executio...

Page 32: ...tion 6 Remote Operating instruction 7 in PDF format is stored on the corresponding marked installation CD and the delivered USB memory stick Use the USB memory stick also to archive your application programs and initalisation files ini resp configuration files cfg For installation of ProNC please read the operating instruction ProNC chapter 3 4 4 configuration dialog 6 For installation of Remote p...

Page 33: ...ead spray cooling unit cooling medium HL4 isel special grease for central lubrication o fat cartridge article number 299032 0002 o greaser article number 299032 0003 CAD CAM software isyCAD CAM 2 5 Galaad Kay Lancelot ProNC 6 Remote 7 accessories air pressure air consumption pneumatic vacuum pump 4 6 bar 100 150 l min 1 nozzle cold air nozzle 3 10 bar 100 151 l min cover of the tool changer 3 6 ba...

Page 34: ...er in case of standard accessory is assembled and connected primed factory made The operation air pressure is 7 5 bar The tool length measuring sensor in case of standard accessory for automatically tool length measurement before or behind the tool change is mounted on the right front side of the clamping plane For setup the tool changer system including tool length measurement please pay attentio...

Page 35: ...einhard 49 0 6659 981 771 fred reinhard isel com Fax 49 0 6659 981 776 Engineering support Frank Hecht 49 0 6659 981 763 frank hecht isel com Frank Jansen 49 0 6659 981 765 frank jansen isel com Please visit our Homepage www isel germany de or order the current catalogue isel From components to Systems Our Newsletter informs you per email about new products applications and improvements In our pla...

Page 36: ... shafts in an interval of about 500 1000 hours of operation Please use the grease gun available as accessories for centralized and the associated specialty grease If you use oil please lubricate in an interval of about 100 200 hours of operation Lubricate not too much at once the wave rails and steel rails must not swim in the grease 9 2 1 Basic lubrication The drive components are lubricated at t...

Page 37: ... well as solvent temperature range 25 C till 200 C fail safe 300 C up to six fold service life extension extremely good adhesion to metal surfaces Classification and marking complies with the EC directives 67 548 EC and 88 379 EC water hazard class 1 Before you start up lubrication of the axis 1 Move the X axis and Y axis to the centre of the traversing area and the Z Axis up to their reference po...

Page 38: ...mounted traverse axis there are two black or white plastic stoppers They can be reached from the operating position when the door cover is open Under the plastic stoppers there are the grease nipples for the X axis central lubrication Pull the stoppers out and lubricate the axis Put the grease gun over the viewable and accessable grease nipples and press the grease gun When finished push the stopp...

Page 39: ...is mounted to the X axis you can find the grease nipples on the right side seen from the operating position This place can be reached from the operating position when the door cover is open Use the grease nipples for the Y axis central lubrication Put the grease gun over the viewable and accessable grease nipples and press the grease gun Also have a view at the following detail picture FlatCom 20 ...

Page 40: ...nel of the X axis there is one black or white plastic stopper at the lower side of linear unit It can be reached from the operating position when the door cover is open Under the plastic stopper there is the grease nipple for the Z axis central lubrication Pull the stopper out and lubricate the axis Put the grease gun over the viewable and accessable grease nipple and press the grease gun When fin...

Page 41: ...uest Note 2 there chapter 4 1 4 Dialog for Status request Emergency stop switch is unlocked unlock Emergency stop switch software works not correctly main switch not switched on switch on main switch power supply for the power amplifiers not switched on power amplifiers by pressing POWER button CAN bus connection between the CAN nodes not correctly check CAN bus cables plug ins and CAN node addres...

Page 42: ...og for Status request Frequency converter for working spindle defect Check Frequency converter for working spindle defect wrong signaling parameters Spindle Start selected Check and modify signaling parameters Spindle Start mode selection switch in position TEST switch mode selection switch to position AUTO Door cover open Close door cover red LED at the frequency converter is blinking Fault in th...

Page 43: ... Internet is done in three steps 1st Step You get in touch with our service department by telephone or email to demand a consultation remote diagnosis The operator working with the CNC machine becomes participant the service technician from isel Germany acts as consultant 2nd Step The consultant will send per email the Windows program NV_o2o_Participant_EN exe to the participant The participant st...

Page 44: ...ry CNC machinery Type FlatCom Assembly instruction Operating instruction for FlatCom Series M L and XL page 44 12 Technical Data of CNC Machine CNC Base machine 12 1 Clamping area and traversing range FlatCom Series M ...

Page 45: ...CNC Base machinery CNC machinery Type FlatCom Assembly instruction Operating instruction for FlatCom Series M L and XL page 45 12 2 Clamping area and traversing range FlatCom Series L ...

Page 46: ...CNC Base machinery CNC machinery Type FlatCom Assembly instruction Operating instruction for FlatCom Series M L and XL page 46 12 3 Clamping area and traversing range FlatCom Series XL ...

Page 47: ... without a tool In concordance with MD 2006 42 EC this is the reason why there is no clearly definition of application purpose of this base machine So FlatCom base machine is always delivered without CE mark For this CNC base machine the Declaration of Incorporation is valid An FlatCom machine is always delivered as closed variant with sliding door cover and with clear panes material Polycarbonate...

Page 48: ...ear units with precision steelshafts and ball circulation skid clearance free adjustable Drive elements Ball screw assemblies adjustable backlash free Control cabinet 5 1 with AC net input 1 phase 230VAC 50 60 Hz 1 phase input L1 N PE Net fuses 16A slow Control cabinet 5 2 with AC net input 3 phase 400VAC 50 60 Hz 3 phase input L1 L2 L3 N PE Net fuses 10A slow Net fuses inside the System module IS...

Page 49: ...pplication results from the kind of tool mounted on a moveable axis tool milling tool usage for milling drilling tool engraving tool usage for engraving tool metering device usage for metering tool water jet nozzle usage for water jet cutting and so on In the new at 29 12 2009 legally binding machine directive 2006 42 EC the term partly completed machinery is defined as follows quote from EC direc...

Page 50: ...inciples EN ISO 13857 2008 Safety of machinery Safety distances to avoid reaching of dangerous regions with upper and lower extremities EN 349 1993 Safety of machinery Minimum distances to avoid bruising of parts of the body EN 953 1997 Safety of machinery Guards general requirements for the design and construction of fixed and moveable guards EN 954 1 1996 Safety of machinery Safety related parts...

Page 51: ...ety of machinery fundamental terms general principles of design Part 1 Basic terminology methodology EN ISO 12100 2 2003 Safety of machinery fundamental terms general principles of design Part 2 Technical principles EN ISO 13850 2008 Safety of machinery Emergency Halt Design guidelines EN 14121 1 2007 Safety of machinery Risk assessment Part 1 Guidelines EN 60204 1 2006 Safety of machinery Electri...

Page 52: ...CNC machinery Type FlatCom Assembly instruction Operating instruction for FlatCom Series M L and XL page 52 14 Exploded views spare parts lists 14 1 FlatCom 20 Figure Exploded view CNC Base machine FlatCom 20 without tool ...

Page 53: ...chwenkarm mit Montagen 8 623025 2070 1 DZ 2070 4 Verbindungsplatte X Achse LES21 LES20 DZ2070 9 623025 2071 1 DZ 2071 4 Verbindungsplatte Z Achse LES21 LES20 DZ2071 10 219211 1000 2 FlatCom Energieführungskette 9 L 1m 11 219211 9000 2 Anschluss für Energieführungskette 9 12 567160 9091 1 Haubenschalter AZM170 L 4m 13 891124 0101 8 Zylinderschraube DIN 6912 8 8 M 6 x 10 14 891124 0251 12 Zylindersc...

Page 54: ...NC Base machinery CNC machinery Type FlatCom Assembly instruction Operating instruction for FlatCom Series M L and XL page 54 14 2 FlatCom 30 Figure Exploded view CNC Base machine FlatCom 30 without tool ...

Page 55: ...70 1 DZ 2070 4 Verbindungsplatte X Achse LES21 LES20 DZ2070 9 623025 2071 1 DZ 2071 4 Verbindungsplatte Z Achse LES21 LES20 DZ2071 10 219211 1000 2 FlatCom Energieführungskette 9 L 1m 11 219211 9000 2 Anschluss für Energieführungskette 9 12 567160 9091 1 Haubenschalter AZM170 L 4m 13 891124 0101 6 Zylinderschraube DIN 6912 8 8 M 6 x 10 14 891124 0161 2 Zylinderschraube DIN 6912 8 8 M 6 x 16 15 891...

Page 56: ...NC Base machinery CNC machinery Type FlatCom Assembly instruction Operating instruction for FlatCom Series M L and XL page 56 14 3 FlatCom 40 Figure Exploded view CNC Base machine EuroMod 40 without tool ...

Page 57: ...5 2070 1 DZ 2070 4 Verbindungsplatte X Achse LES21 LES20 DZ2070 9 623025 2071 1 DZ 2071 4 Verbindungsplatte Z Achse LES21 LES20 DZ2071 10 219211 1000 1 FlatCom Energieführungskette 9 11 219211 9000 1 Anschluss für Energieführungskette 9 12 567160 9091 1 Haubenschalter AZM170 L 40 13 891124 0101 6 Zylinderschraube DIN 6912 8 8 M 6 x 10 14 891124 0161 2 Zylinderschraube DIN 6912 8 8 M 6 x 16 15 8911...

Page 58: ...CNC Base machinery CNC machinery Type FlatCom Assembly instruction Operating instruction for FlatCom Series M L and XL page 58 14 4 FlatCom 50 ...

Page 59: ...2070 1 DZ 2070 4 Verbindungsplatte X Achse LES21 LES20 DZ2070 9 623025 2071 1 DZ 2071 4 Verbindungsplatte Z Achse LES21 LES20 DZ2071 10 219211 1000 1 FlatCom Energieführungskette 9 L 1m 11 219211 9000 1 Anschluss für Energieführungskette 9 12 567160 9091 1 Haubenschalter AZM170 L 40 13 891124 0101 6 Zylinderschraube DIN 6912 8 8 M 6 x 10 14 891124 0161 2 Zylinderschraube DIN 6912 8 8 M 6 x 16 15 8...

Page 60: ...sel Germany AG 02 2009 4 Operating instruction CNC Operating panel Manual for CNC Operating panel iBP10 iBP17 isel Germany AG 07 2008 5 1 Wiring diagrams Control cabinet with isel CAN CNC Control 1 phase power supply 230 VAC Wiring diagrams and part lists for the Control cabinet with IMD10 IMD20 ISM10 and Control PC isel Germany AG 07 2009 5 2 Wiring diagrams Control cabinet mit isel CAN CNC Steue...

Page 61: ...se machine 7 8 CNC machine 7 8 complete machinery 6 compressed air 33 consultant 43 CoolMin 33 cover interlock 25 D Declaration of Conformity 47 Declaration of Incorporation 47 download 3 E Emergency HALT 10 EMERGENCY STOP 24 EN 60204 1 28 EN ISO 62061 25 Engineering support 35 F flatbed machinery 22 G grease cartridge 36 grease gun 36 Grease properties 37 I ISO 11014 1 36 M manual unlock of the d...

Page 62: ...0 portal machinery 22 positioning accuracy 14 Q QC10 6 13 R rapid traverse velocity 9 reasonably foreseeable misuse 9 reference point 22 Renishaw 14 residual risk 11 Residual risk 10 right hand rule 23 Risk of injury 30 S Safety Circuit Module 25 safety instructions 2 safety interlock 26 scope of delivery 12 seal lips 36 space requirement 16 standstill monitoring 25 System module ISM10 12 T Techni...

Page 63: ...inery Type FlatCom Assembly instruction Operating instruction for FlatCom Series M L and XL page 63 V vacuum clamping 20 Vakufit 33 W Weight 48 WIBU USB dongle 31 Windows operating system 27 wiring diagrams 20 work piece zero 21 ...

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