Isel ICP 3020 Operating Instructions Manual Download Page 2

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ICP 3020 / ICP 4030 iMC-P

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Machinery directive 2006/42/EC

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danger.

Warning!

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person’s health,

physical injury or death.

Warning! Dangerous voltage!

Warning of danger from electricity. Ignoring can lead to serious injury or
death.

Attention!

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damages and malfunctions of the machinery

Information:

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Observe the safety instructions

Before you take the CNC machine ICP in operation, working with the
machine or make additions or changes to the wiring of the machine
/ in the housing of the machine, make sure to read carefully the
safety instructions in this manual. (Chapter

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Summary of Contents for ICP 3020

Page 1: ...isel Germany AG Bürgermeister Ebert Straße 40 D 36124 Eichenzell Tel 06659 981 0 Fax 776 Operating Instruction CNC compact machinery type model ICP iMC P ICP 3020 ICP 4030 ...

Page 2: ...om electricity Ignoring can lead to serious injury or death Attention This Symbol indicates 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 take the CNC machine ICP in operation working with the machine or make additions or changes to the wiring of th...

Page 3: ...alid 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 for the controlle...

Page 4: ... 5 Tooling machine 13 5 5 1 Enclosure with safety interlock 14 6 Assembly and operation 15 6 1 Safety notes 15 6 2 Overview 16 6 3 Connectors 17 6 3 1 Connectors on the back side of the machine 17 6 3 2 Control elements on front side of the machine 18 6 3 3 Stepper motor control assembly 20 6 4 Connectors of the stepper motor control 21 6 4 1 Access to stepper motor control and their components 21...

Page 5: ... mode 34 8 Maintenance 35 8 1 Cleaning the machine 35 8 2 Lubrication 35 9 Faults 37 10 Accessories 38 11 Technical data 39 11 1 Dimensions and weight 39 11 2 Drive 39 11 3 Electrical data 39 12 Declaration of conformity for complete machinery 40 13 Bibliography 41 14 Index 42 15 Appendix 43 ...

Page 6: ... amplifiers up to 4 axes with 4A rated current o base board with processor core module o security circuit module SC module o 48V and 24V power supply unit o Function keys and emergency stop switch on the machine front side o net cable o communication cable drilling milling machine with 3 mm collet wrench for collet wrench opening 22 clamping set lever stop rails 5 mm hexagon wrench triangular wren...

Page 7: ...ose resp specific application and therewith a specific usage The usage results from the kind of tool which is mounted on a moveable axis e g 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 The manufacturer isel Germany AG is able to effect a legal prescribed risk assessmen...

Page 8: ...aluminium copper brass plastics e g GRP fibreglass wood o The processing of magnesium is prohibited because of fire o During the processing of steel stainless steel only engraving or a processing with low cutting forces is possible o It shall not be used milling spindles with a tool holder greater than ISO 25 or HSK 25 hollow shank taper The speed of the spindle drive may not be higher than the co...

Page 9: ... of the CNC base machine you are responsible for taking appropriate protective measures based on your risk assessment to comply the requirements for the machine according to Machinery Directive 2006 42 EC During operation of the CNC machine we recommend the wearing of appropriate hearing protection and appropriate protective equipment e g protective glasses Be careful that work pieces are tightly ...

Page 10: ... table must be avoided 3 1 Occupational safety By following the instructions at work may present a risk of persons and or the device can be prevented Not observing these instructions may cause a danger to persons and goods by mechanical or electrical influences or the failure of the device Not observing the safety results in the loss of any claims 3 2 Operators The machine may be operated and main...

Page 11: ...nostic 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 form tolerance The...

Page 12: ...achine in order to operate and arrange the processing plus approx 10 cm behind the machine to allow for connectors The hood of the housing opens upwards Thus the required total height is approx 1 2 meters Dimensions and space requirement Keep the triangular wrench always outside of the machine during transportation When planning the floor space for the CNC machine regard the universal access for i...

Page 13: ... the triangular wrench always outside of the machine during transportation 5 3 Installation of the CNC machine The clamping processing area of the CNC machine and all axes are aligned precisely at right angles from the factory Never loosen the fastenings of the axles or the mounting bracket in which the transverse axis X fitted axis Otherwise the machine must be re measured by a technician from ma...

Page 14: ... tools with a maximum shaft diameter of 6 35 mm standard 3 mm other diameters see Accessory Use two SW 22 open end wrenches for changing the collet The tooling machine is only enabled by the software You can manually adjust the rotation speed of the machine using the 1 wheel Switch off the main switch of the ICP for dismantling the tooling machine Remove the electricity cable from the coupler term...

Page 15: ...echnical data The tooling machine is only useable if the POWER button is lighted the hood is closed the tooling machine switch is set set to ON and the software is communicating with the control 5 5 1 Enclosure with safety interlock CNC machinery of type ICP have a homogeneous machine frame e g the enclosure is not removable The transparent panes material polycarbonate mounted in the machine frame...

Page 16: ...sts additional actors or sensors already connected 6 1 Safety notes The work on the electrical installation must be performed by authorized and trained personnel Any changes to the electrical installation will void the warranty and CE conformity In additions to the machine e g spindle drives actuators sensors etc the operator is responsible for ensuring that all safety rules are followed in accord...

Page 17: ... page 16 safety hood with solenoid interlock bezel with control elements working tool milling machine Y axsi longitudinal axis X axis transverse axis Z axis vertical axis safety glass tool collar Ø 43mm machine feets height adjustable 6 2 Overview ...

Page 18: ...and control PC is realized via a serial interface RS232 Use the delivered communication null modem cable for connection A software protocol realizes the faultless transmission of the ASCII characters Data transfer parameters 19200 baud 8 data bits 1 stop bit no parity 2 net input module with main switch and fuses 110 230V AC 50 60 Hz wide range net input module with main switch and fuses 2 x 6 3A ...

Page 19: ...If you push the emergency stop switch the motor power supply will be switched off immediately and any axes motion will be stopped The main power supply voltage of 115 230VAC lies still on the device only the motor power supply voltage for the amplifiers is switched off 2 power button Use this button to switch on motor power supply voltage for the motor power amplifiers Conditions for switch on Mai...

Page 20: ...un out Ensure that in test mode key switch on TEST only authorized personal operates on the machine 4 start button If you press the start button in CNC mode see chapter 7 4 1 a saved user program in the flash memory will be executed You cannot use the start switch in DNC mode 5 stop button If you press the stop button in CNC mode an active user program axis motion will be stopped You can continue ...

Page 21: ...ICP 3020 ICP 4030 iMC P Operating instruction page 20 6 3 3 Stepper motor control assembly ...

Page 22: ...connect to the terminals of the step motor control additional components e g frequency solenoid valves sensors actuators etc Open the housing of the stepper motor Generally it is not necessary to open the case of the stepper motor control Opening the housing cover may only be performed by authorized and trained personnel After you have removed the cover plate of the machine remove the housing of t...

Page 23: ...n of a stepper motor with brake is only on the connector of the Z axis possible At this jack the switching signal 24 V to pin 6 for the motor brake is provided Remote security circuit interface 8 pin socket Use this connector to include the controller into a higher ranked security circuit system Please note that the external power input is only useable if the power button from the controller front...

Page 24: ...digital inputs 8 pin connector The controller has 8 digital user inputs Use these inputs to connect external devices like sensors switches or outputs from other devices All inputs are opto decoupled If 24VDC lies on the input a logical HIGH is signalized Not connected e g switch open a logical LOW is signalized Do not short 24VDC potential of the controller with GND or case ground Use external eme...

Page 25: ...like relays or inputs from other devices The maximum load of each relay output is 24 VDC 300 mA Do not short 24VDC potential of the controller with GND or case ground If you have pushed the emergency stop switch all states of the binary user outputs will be maintained and not reset The binary user output 1 output 8 must be wired as shown opposite The transistor outputs output 1 8 can be rated with...

Page 26: ...n description 1 24VDC 2 n u 3 n u 4 make contact 1 potential free contact 5 analog 0 10V 6 GND 7 n u 8 make contact 1 potential free contact 9 GND pin description 1 coil break contact 2 switch 1 1 bridge to pin 3 if no safety door is used 3 switch 1 2 bridge to pin 2 if no safety door is used 4 switch 2 1 bridge to pin 5 if no safety door is used 5 switch 2 2 bridge to pin 4 if no safety door is u...

Page 27: ...ove the cover plate by loosen the screws all around on the top of the controller case Connect the 3 pin wire from connector Spindle 230V inside the controller with the for you necessary connector on the security circuit module Ex factory the controller is delivered with the connection to X1 that means for a working spindle without speed control Connector X3 for frequency inverter with working spin...

Page 28: ... execution or storing of a command with the quitting signal 0 char 48 or returns an occurred error with an ASCII character unequal 0 Data transfer parameters 19200 baud 8 data bits 1 stop bit no parity 6 5 Adjusting the stepper motor power amplifiers The CNC machine ICP 3020 4030 iMC P has four stepper motor power amplifiers MD24 Settings for rated current step resolution and current reduction tak...

Page 29: ... 5 step resolution 1 6 step resolution 2 7 step resolution 3 8 step resolution 4 Current setting DIP switch 1 2 3 Use the DIP switches 1 2 and 3 to set the current of the motor The following table shows the motor current RMS setting for the different switch positions peak current A rated current A SW1 SW2 SW3 1 00 0 71 ON ON ON 1 46 1 04 OFF ON ON 1 91 1 36 ON OFF ON 2 37 1 69 OFF OFF ON 2 84 2 03...

Page 30: ... Use the DIP switches 5 6 7 and 8 to set the step resolution Setting the factor to a higher value causes a smooth motion of the motor but the maximum reachable velocity will taking down Also the motor torque will be reduced to 75 in microstep mode The following table shows the DIP switch settings for the different step resolutions micro steps steps rev 1 8 motor SW5 SW6 SW7 SW8 2 400 OFF ON ON ON ...

Page 31: ...al defect loose parts is identifiable on the machine all parts and wirings are available the machine is placed according to the regulations 7 2 1 Connections connect communication cable null modem cable between PC notebook and machine connect main power supply cable Configuration if not already preset Remove the backplane of the machine by screwing out the nine hexagon screws Also remove the earth...

Page 32: ...s the POWER ON button to power up the motor amplifiers The POWER ON button should now be lighted Machine is now ready for operation Choose the operation mode Use the CNC compact machine ICP in CNC or DNC mode see chapter 7 4 7 3 Software installation For operation and programming the machine in CNC mode you need the software PALPC 2 1 on version 2 0 1 04 0 or higher For operation of the machine in...

Page 33: ... 7 4 1 Using the ICP 3020 ICP 4030 in CNC mode The CNC mode automatic mode CNC mode is the program controlled mode of the stepper motor control of the machine That means that a user program which is saved in the controller s memory flash will be executed till the end During the automatic mode CNC mode you can stop the execution of the active user program by pressing the STOP key on the front side ...

Page 34: ... in 800 steps rev The value for the spindle gradient is depending by the machine type The max step frequency is 40KHz full step For a simple test of the machine click on Transfer Terminal Type into the terminal window the following commands 0V request version information 07 initialize 3 axis 0R7 reference run 3 axis Every command is receipt by a return code 0 no error Please note the factory setti...

Page 35: ...Remote ProNC Machinery of type ICP 3020 ICP 4030 iMC P have each 8 digital inputs and outputs which can be used by the user Important notes During an axis movement it is not possible to read a digital input by the software because the stepper motor controller has to send an acknowledgement character before every new command During an axis movement it is not possible to set a digital output by the ...

Page 36: ...nd require no special maintenance Clean the perspex windows with a non abrasive fluid cleaner 8 2 Lubrication The shaft guides and drive shafts are provided with a long term lubrication ex works Depending on the load you should grease the shaft guides and drive shafts approx all 500 1000 operating hours 1 Use usual rolling bearing grease for that purpose Ex works the shaft guides and shafts are lu...

Page 37: ...te through the now visible lubricating nipple You access the shaft guides again through the sealing lips At the Z axis you must first take the tooling machine from its support Remove the three plugs and push the sledge completely down You can apply some oil onto the shaft guides through the two side holes The lubricating nipple for the drive is now behind the front opening ...

Page 38: ...power amplifiers by pressing POWER button motor cables not connected check motor cables no communication via serial interface incorrect COM port selected select correct COM port incorrect baud rate select 19200 baud milling spindle is not working incorrect setting in the spindle module DLL only DNC mode check settings and change if applicable switch on the milling spindle only 100 230 V is switche...

Page 39: ...t unit spray cooling unit cooling medium HL4 work lighting CAD CAM software isyCAD CAM 2 5 Galaad Lancelot ProNC 6 Information for compressed air connection of accessories To use the optional vacuum clamping system or the tool changer and collets of the working spindle it s necessary that the location of the machine has a compressed air connection accessories air pressure air consumption pneumatic...

Page 40: ...ndard version Y axis mm 10 10 Z axis mm 10 10 motor in standard version X Y Z W 120 120 120 120 120 120 11 3 Electrical data Net input net power supply voltage 100 230VAC 50 60 Hz 16A fuse net input 2 x 6 3A 250V time lag ground complies with protection class 1 Stepper motor power amplifiers max peak current per amplifier 4 2 A max rated current per amplifier 3 0 A supply voltage of the power ampl...

Page 41: ...hinery 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 of control systems Part 1 General princ...

Page 42: ...scription MD24 MD28 isel Germany AG 01 2010 2 PAL PC programming instruction Software manual PALPC isel automation 06 2004 3 Remote Operation and output program for ISO NCP and CNC files Software manual Remote isel automation 06 2005 Up to date Operating instructions and manuals for download you can find here www isel data de manuals ...

Page 43: ... 18 Faults 35 I instructed persons 9 interface impulse control 22 iSA36 isel CoolMin 36 isel Vakufit 36 M main spindle 37 movement area 37 N null modem cable 29 O Operation mode switch 18 operation modes 31 operators 9 P pass through height 37 peak current 37 processing area 12 R rated current 37 Renishaw QC10 10 RS232 17 26 S safety door 7 safety interlock 14 security circuit interface 21 serial ...

Page 44: ..._____________________________ return to ______________________________________________ quantity item number designation invoice no delivery note no please add copy serial number Cause for Complaint a commercial complaint O wrong delivery O wrong quantity O____________________________________________ b technical complaint error description When does the fault occur O constantly O temperature depend...

Page 45: ...ble probable operator error the product is self consciously returned against a service charge 4 Wrapping We can only accept returned products in original isel packing or equivalent wrapping The warranty claim is endangered by missing original or inappropriate wrapping Resulting transport damages cause the expiration of the warranty claim 5 OEM products Products which were not delivered by us are r...

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