Isel ICP 4030 iMC-P Assembly Instructions/Operating Instructions
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Isel ICP 4030 iMC-P Assembly Instructions/Operating Instructions

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Assembly instructions for CNC basic
machines (incomplete machines)
Operating instructions for CNC machines
(complete machines)
Type/Model: ICP 4030 iMC-P
© isel Germany AG, January 2018, German

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Summary of Contents for Isel ICP 4030 iMC-P

  • Page 1 Assembly instructions for CNC basic machines (incomplete machines) Operating instructions for CNC machines (complete machines) Type/Model: ICP 4030 iMC-P © isel Germany AG, January 2018, German...
  • Page 2 ICP 4030 iMC-P On these operating instructions Abbreviations Machinery Directive 2006/42/EC Symbols used In this manual, you will find various symbols to draw your attention to important information / facts and risks: Warning! Warning of hazards that may lead to adverse health effects, physical injury or death.
  • Page 3 For all other machine parts and components, to which CE safety guidelines apply, start-up is prohibited until all appropriate requirements are met. The company isel Germany AG accepts no responsibility or liability if you make changes to the machine without the manufacturer's consent, which affect the CE conformity of the machine.

  • Page 4: Table Of Contents

    ICP 4030 iMC-P Contents Introduction ......................5 Intended use, foreseeable misuse ..............7 Safety notices....................10 General safety notices ................. 10 Special safety notices .................. 12 Setting up and connecting the CNC machine ..........14 Scope of supply ................... 14 Delivery status ex works (quality assurance) ..........
  • Page 5 ICP 4030 iMC-P 6.5.1 Manufacture of operational readiness 6.5.2 Production: Processing / manufacturing a component 6.5.3 Ending the operational readiness Operating modes ..................43 6.6.1 Use of the ICP 4030 in CNC operation 6.6.2 Use of the ICP 4030 in DNC operation Cleaning, lubrication and maintenance ............

  • Page 6: Introduction

    For each basic machine / machine delivered, a measurement and test report with the customer's order number is kept at the manufacturer isel Germany AG, and can be requested by you as a buyer. All basic machines / machines are measured with circularity tester QC20 by Renishaw®...
  • Page 7 ICP 4030 iMC-P The statements in these operating instructions apply to the following equipment / technical level of the CNC machine control: • all motor output stages are fitted with Standstill monitoring (from 01/07/2008) • the operating software used is: ProNC /6/ / Remote /7/ from software version V1.46.2.1...

  • Page 8: Intended Use, Foreseeable Misuse

    Application for sticking, dispensing Tool = water jet nozzle Application for water jet cutting etc. As the manufacturer, isel Germany AG can carry out the statutory required risk assessment for CNC machines. CNC machines are supplied with housing. January 2018...
  • Page 9 Directive applies; Every isel-CNC basic machine delivered without a tool and therefore not for a specific application, is partly completed machinery pursuant to the Machinery Directive 2006/42/EC.
  • Page 10 ICP 4030 iMC-P • CNC machines for milling: The CNC cutting machines are designed for cutting / drilling the following materials: Aluminium, copper, brass, plastics (e.g. GRP/fibre glass), wood Processing magnesium is prohibited due to the risk of fire. In the processing of steel / stainless steel only engraving works or processing with low cutting forces is possible.

  • Page 11: Safety Notices

    ICP 4030 iMC-P 3 Safety notices Read this section of the Operating Instructions carefully before connecting and operating the machine! As with all technical systems, faultless function and operational safety can only be guaranteed with this machine if the general safety precautions and the special safety instructions are observed during operation.
  • Page 12 ICP 4030 iMC-P 11. The cutting machine may only be operated with original accessories, or accessories approved by the manufacturer. When replacing parts in accordance with these operating instructions, only original parts may be used. No liability shall be accepted for damages caused by the use of non-approved accessories or external parts.

  • Page 13: Special Safety Notices

    7 mm (standard). If you are unsure or have any queries about the choice of tool, please contact the application technology department at isel Germany AG. • The CNC basic machine without a housing or protective hood is a complete machine under the Machinery Directive 2006/42/EG and is supplied without CE marking.
  • Page 14 ICP 4030 iMC-P • For emergencies, you will find an emergency stop switch at the front. This interrupts the power supply to the power electrics (motor output stages) and the frequency converter for the main spindle drive. The shut-down takes place according to stop category 1 (controlled stop and subsequent interruption of the power supply to the drives).

  • Page 15: Setting Up And Connecting The Cnc Machine

    ICP 4030 iMC-P 4 Setting up and connecting the CNC machine 4.1 Scope of supply The machine is delivered fully assembled on a pallet. In the scope of delivery of the ICP 4030, Art no.: 280270 XXX the following are contained: ▪...

  • Page 16: Space Required

    ICP 4030 iMC-P The measurements are done based on the size of the axes to be measured with a radius of 50mm, 100mm, 150mm and 300mm. The shortest axis must always be taken into consideration. Each CNC machine will not be delivered until all parameters are within the prescribed limits.

  • Page 17: Transporting The Cnc Machine

    ICP 4030 iMC-P Always keep the triangular wrench especially when transporting outside the machine When you set up your CNC machine, use only suitable, , secure clamping tools (see chapter Accessories). Always make sure the components are sitting tightly. When planning the installation space for the CNC machine, all-round...

  • Page 18: Coordinate System And Reference Point

    ICP 4030 iMC-P 4.6 Coordinate system and reference point The coordinate system of the machine is defined as shown in the illustration, whereby you can freely select (move) the component zero point P0 via the software. The reference point of the machine (machine zero point) is set in front (Y) at the factory on the left (X) above (Z).

  • Page 19: Protective Cover With Solenoid Interlock

    ICP 4030 iMC-P You can also mount many other tools, measuring devices (laser) or other suitable fixtures to the T-slot plate of the Z-axis with appropriate brackets. For the electrical connection, please use the junction box on the Z-axis. If you want to reassemble the machine tool or other tools, you must realign the bracket parallel to the XY plane.

  • Page 20: Design And Operation

    ICP 4030 iMC-P 5 Design and operation On delivery: ▪ all operating elements are already connected to the safety circuit of the control unit. ▪ the main spindle drive is (not speed controlled 230V/500-750W or speed controlled 750W) ▪ additional actuators or sensors are connected according to customer requirements.

  • Page 21: Overview

    ICP 4030 iMC-P 5.2 Overview Z-axis (vertical axis) Machining tool (milling spindle) X-axis right Tool clamping neck Ø 43mm Protective cover with solenoid interlock Safety symbols Y-axis) (longitudinal axis) Front panel with control elements Machine feet (height adjustable) January 2018...

  • Page 22: Connections

    ICP 4030 iMC-P 5.3 Connections 5.3.1 Connections on the back Number Description Description 230V AC power supply unit connection with main switch and mains fuse 2 x 10A slow- Mains connection socket blow; IEC 127 HBC filter with main switch and...

  • Page 23: Front Panel Controls

    ICP 4030 iMC-P 5.3.2 Front Panel Controls Operating elements for the machine controller Description Description Emergency stop Switching off the power supply of the motor output stages and the working spindle. button 3 Power-On button Power supply to the output stages is switched on.

  • Page 24: Structure Of The Stepper Motor Control

    ICP 4030 iMC-P Control elements for the control computer No. Description Description Power button Switching on the control unit Power LED Operating display of the control computer HDD-LED Hard disk access indicator USB sockets USB 2.0 sockets for USB devices (USB stick, WIBU etc.) 5.3.3 Structure of the stepper motor control...

  • Page 25: Connections On The Stepper Motor Controller

    ICP 4030 iMC-P 5.4 Connections on the stepper motor controller 5.4.1 Safety notices All work on the electrical installation must only be carried out by authorised and trained personnel. Any changes to the electrical installation will void the warranty and CE conformity. When adding to the machine (e.

  • Page 26: Connections

    ICP 4030 iMC-P 5.4.3 Connections Motor - Motor connection X-, Y-, Z-, A-axis, Sub-D9-pole socket The motor modules (CNC axis) are connected to these SubD-9 sockets. This plug may only be connected or disconnected when the controller is switched off. Failure to do so may result in damage to...
  • Page 27 ICP 4030 iMC-P External emergency stop not used: Pin 5 and 6 bridged Pin 7 and 8 bridged If an external emergency stop switch is used, the length of the connection cable is max. 5m. Using an external power button:...
  • Page 28 ICP 4030 iMC-P Input - Digital inputs, 8-pole socket The controller has 8 digital inputs (Input 1... 8). External devices (sensors, switches, outputs of other devices) can be connected via these. The inputs are opto-decoupled. If an input is connected with +24VDC, a logical HIGH signals this. If it is not switched on (e.
  • Page 29 ICP 4030 iMC-P Analogue - Out - Sub-D9-pole socket With this connector, an external frequency inverter and the associated working spindle can be connected via an analogue 0..10V output can be controlled. Description +24VDC n.c. n.c. Closer 1 (potential-free contact) Analogue 0 ...10V...
  • Page 30 ICP 4030 iMC-P Milling spindle - 100 - 230V, connection 3-pole This output can be used to connect either a milling spindle without speed control or a frequency converter with associated main spindle drive (e.g. iSA 750) with speed control. Depending on the application, the power supply line of the milling spindle or the frequency inverter must be connected to the safety circuit module.

  • Page 31: Setting The Stepper Motor Output Stages

    ICP 4030 iMC-P RS232 (PC) - Programming interface A serial interface (RS232) is used for data transmission between the control of the machine ICP 3020 / 4030 and a control computer. The communication cable (zero modem cable) supplied should be used for the connection. A software protocol enables error-free transmission of ASCII characters.
  • Page 32 ICP 4030 iMC-P Opening the housing Remove the rear panel of the machine and the housing cover of the control unit (see Chapter 5.4.2). The stepper motor output stages are arranged next to each other. Configure the individual stepper motor output stages according to the following...
  • Page 33 ICP 4030 iMC-P Current reduction (DIP switch 4) Since the holding torque of stepper motors is higher than the torque, a holding torque similar to that of the torque can be achieved by means of a reduced current. As a result, for example, with a current reduction of 25%, the power dissipation is reduced by 50%, as the power decreases square to the current.

  • Page 34: Installation And Commissioning

    ICP 4030 iMC-P 6 Installation and commissioning 6.1 Safety notices Observe the technical data of the machine and the pin assignment in Chapter5.3. Failure to observe the safety instructions may endanger persons and objects due to mechanical or electrical influences or failure of the device.

  • Page 35: Software Installation

    ICP 4030 iMC-P First start-up You should carry out the following steps during the first start-up: Switch on the machine with the main power switch (rear side) • Check that the emergency stop switch is pulled out / unlocked. •...
  • Page 36 ICP 4030 iMC-P Alternatively, you can also start the installation assistant. This assistant will take you through the installation. To operate and program the control system in CNC mode, you need the programming software PALPC from version 2.01.04.0. To operate the machine in DNC mode, you need the control software Remote (optional ProNC) from version 1.45.6.2 with the control...

  • Page 37: Mode Automatik - Production On The Cnc Machine

    Start CNC operating software Remote, close hood of the CNC machine Set mode selector switch to AUTO Press Power-On button on the CNC operating panel Result (the background image with isel-logo and text is the default single colour): January 2018...
  • Page 38 ICP 4030 iMC-P Reset the motion controller -> all drive units are initialised and their operational readiness established. Do a reference run of all axes (standard setting: Z-axis is first referenced) -> after this control action the numerical axes can be moved manually Move the axes manually to a position in which the tool can be clamped in the clamping device of the working spindle;...
  • Page 39 ICP 4030 iMC-P Open processing programme (here: the NCP file Isel.ncp): January 2018...
  • Page 40 ICP 4030 iMC-P Result (text view) January 2018...
  • Page 41 ICP 4030 iMC-P Result (graphic view) 8: for safety sake, reference Z-axis: 40 / 71 January 2018...

  • Page 42: Production: Processing / Manufacturing A Component

    ICP 4030 iMC-P 6.5. 2 Production: Processing / manufacturing a component /operations Set processing mode to automatic operation: Press START button on the CNC operating panel -> processing starts (text view) January 2018...

  • Page 43: Ending The Operational Readiness

    ICP 4030 iMC-P 3: Wait for end of processing; if the component has been completely processed, the axes of the CNC machine (Z axis first, followed by the X and Y axes) automatically go to the park position when the following output settings (Settings ->...

  • Page 44: Operating Modes

    ICP 4030 iMC-P 6.6 Operating modes The operating system (firmware of the processor core) supports both the: • CNC mode of the controller: ▪ Control of the ICP processes the stored user programme independently without PC coupling ▪ Use of the programming software PALPC for user programming and download of the user programme into the flash memory of the control unit.

  • Page 45: Use Of The Icp 4030 In Dnc Operation

    DNC mode, please refer to the Remote operating instructions /3/. Use of digital inputs and outputs and signalling in Remote/ProNC The machines of the type ICP 3020 / ICP 4030 iMC-P each have 8 digital inputs and outputs, which can be used by the user. Important notices!!!

  • Page 46: Cleaning, Lubrication And Maintenance

    The EC safety data sheet as per Directive 93/112/EEC and ISO 11014-1 can be requested from the factory. 7.2.2 Re-lubrication To re-lubricate the linear bearings with shafts, only the isel special grease should be used. The grease required can be ordered using the following article numbers: •...

  • Page 47: Lubrication Points Of The Linear Axes X, Y And Z

    ICP 4030 iMC-P Grease characteristics: The isel special grease has the following characteristics: • huge reduction in wear • considerably less consumption • can be mixed with lithium and calcium greases • water-repellent • highly resistant to cold-, hot- and salt water and solvents •...
  • Page 48 ICP 4030 iMC-P To lubricate the X-axis, slide the carriage to the left*, remove the plastic plug on the left side of the machine and lubricate through the greasing nipple, which is now visible. The guide rails can be accessed through the sealing lips.

  • Page 49: Maintenance Intervals According To Operating Hours Counter

    ICP 4030 iMC-P Maintenance intervals according to operating hours counter The software operating hours counter integrated in the isel control software ProNC /6/ or Remote /7/ informs the operating personnel about the expiry of the current maintenance interval: green bar: Minimum...

  • Page 50: Maintenance Activities

    ICP 4030 iMC-P If, when starting the isel control software ProNC or Remote, the message indicates that maintenance is required, perform the following maintenance activities 7.4 Maintenance activities The following tasks must be carried out at the end of a maintenance interval: •...

  • Page 51: Returning Used Electrical And Electronic Equipment For Disposal

    ICP 4030 iMC-P 8 Returning used electrical and electronic equipment for disposal Collection Users of electrical and electronic equipment are required to collect waste separately in accordance with the country-specific regulations. Used electrical and electronic equipment may not be disposed of with unsorted household waste.

  • Page 52: Remote Diagnosis

    The connection is established via the internet in three steps: 1. Step You contact by phone or email our support team and ask for a consultation. The operator on the CNC machine becomes the subscriber, the isel-service technician acts as an adviser.

  • Page 53: Accessories

    • Main spindle drives iSA 500,750,900 • Machining spindle UFM 500, UFM 1050 • Vacuum clamping system isel-Vakufit • Cold air cooling isel-CoolMin: Cooling device with cold air nozzle (up to -20°C) • Extraction device • Spray-/cooling device, cooling agent HL4 •...

  • Page 54: Technical Data

    ICP 4030 iMC-P 11 Technical data 11.1 Dimensions and weight Data ICP 4030 Dimensions (W x H x D): [mm] 9 x 836 x 901 Travel ranges X-axis [mm] Y-axis [mm] Z-axis [mm] Speed (X/Y/Z at 10mm pitch) 0/100/80 mm/s 11.2 Electrical Data...

  • Page 55: Malfunctions

    ICP 4030 iMC-P 12 Malfunctions Fault Cause Solution No mains connection Check circuit power supply plug, power strip System will not switch Main switch not Switch main switch on switched on Disconnect mains Fuse faulty plug Replace fuse Cover not closed...

  • Page 56: Declaration Of Conformity Or Declaration Of Incorporation

    All isel CNC basic machines, supplied with a tool (e.g. processing or engraving spindle, dosing unit, sensor like CCD camera or triangulation laser, water jet nozzle, plasma burner or equiv.),are covered by the declaration of conformity...

  • Page 57: Declaration Of Conformity For (Complete) Machine

    ICP 4030 iMC-P 13.1 Declaration of Conformity for (complete) machine EC Declaration of Conformity as per Machinery Directive 2006/42/EC, appendix II A manufacturer isel Germany AG Bürgermeister-Ebert-Str. 40, D-36124 Eichenzell hereby declares that the following product Product description isel-CNC-Machine ICP 4030...

  • Page 58: Declaration Of Incorporation For (Partly Completed) Basic Machines

    ICP 4030 iMC-P 13.2 Declaration of incorporation for (partly completed) basic machines Declaration of incorporation as per Machinery Directive 2006/42/EC, appendix II B The manufacturer isel Germany AG Bürgermeister-Ebert-Str. 40, D-36124 Eichenzell hereby declares that the following product Product description:...

  • Page 59: Exploded Views / Spare Parts Lists

    ICP 4030 iMC-P Exploded views / spare parts lists Fig 4: Exploded view ICP 4030, DU8000 58 / 71 January 2018...
  • Page 60 ICP 4030 iMC-P Parts list ICP 4030 Item No. Item No. Quantity Description Drawing No. 680670 8001 DZ8001 - Chassis ICV 4030 - EC - RAL 7016 - RAL 3003 DZ8001 680670 8024 DZ8024 - Front panel with controls ICV 40-30 - EC...

  • Page 61: Structure Axis Systems

    ICP 4030 iMC-P 14.1 Structure axis systems X-Axis 69 / 71 January 2018...
  • Page 62 ICP 4030 iMC-P Parts list X-Axis Item No. Article number Quantity Description Drawing No. 680524 1250 DZ1250 - Shuttle H22,5 ICP 20-15,30-20,40-30 DZ1250 680524 1328 DZ1328 - Bearing block X-Axis ICP DZ1328 675012 7255 DZ7255 - Shuttle for travel limit switch GOH - Z-Axis...
  • Page 63 ICP 4030 iMC-P Y-axis January 2018...
  • Page 64 ICP 4030 iMC-P Parts list Y-axis Item No. Article number Quantity Description Drawing No. 680534 1244 DZ1244 - Shuttle H22,5 ICP 30-20 DZ1244 680524 1328 DZ1328 - Bearing block X-Axis ICP DZ1328 675012 7255 DZ7255 - Shuttle for travel limit switch GOH - Z-Axis...
  • Page 65 ICP 4030 iMC-P Z-Axis Parts list Z-Axis Item No. Article number Quantity Description Drawing No. 635500 0039V02 Linear guide LFS-12-5 - L=390 - Lubrication hole in the middle DZ2521 890133 0121 TE0174 - Countersunk bolt with Torx 20 M5x12 TE0174...
  • Page 66 ICP 4030 iMC-P Item No. Article number Quantity Description Drawing No. 211135 10372 TE2859 - Ball screw spindle 16x10 - L=372mm TE2859 623065 0102 TE2935 - Flange for belt drive (LF4-6) TE2935 623056 1002 TE5925 - IGP 2520 - LES4 Belt drive - End plate - Limit switch plate...

  • Page 67: Source Directory

    MD24 / MD28 Stepper motor drive module operating instructions, Version 03/2009 PAL-PC Programming Instructions, Version 06/2004 iMC-M / iMC-MP Programming Instructions, Version 03/2012 Operating instructions isel control computer iPC- 25: Manual for the control computer (control PC) iPC-25; isel Germany AG, 06/2014 Remote: Operating and output programme for ISO-, NCP- and CNC files: Manual on the operating interface Remote;...
  • Page 68 ICP 4030 iMC-P ............ Schmersalschalter ............Schrittauflösung ............Schutzleiterstrom ..........Konformitätserklärung ............Sicherheitskonzept ........Kreisformmesssystem QC10 ............Sichtkontrolle ..........Kreisform-Vermessung ............Softwarestand ............Software-Update ............... Spezialfett ............Spitzenstrom ............ Laserinterferometer ............... Start-Taste ............Lieferumfang ..........Stillstandsüberwachung ............... Stop-Taste ........... Maschinenkinematik ............

  • Page 69: Annex

    ICP 4030 iMC-P 17 Annex 17.1 Service card Sender: Company Customer No. Contact/Department Telephone Address Return to Invoice-No. Delivery note Serial Quantit Art. Number Description number (please number enclose copy) January 2018...

  • Page 70: January

    ICP 4030 iMC-P Cause of complaint a) Commercial complaint O Incorrect delivery O Quantity variance b) Technical complaint Error description: When does the error occur? O ongoing O temperature-based O sporadically O after minutes runtime Was the article already in use?
  • Page 71 Packaging We can only accept returned goods in isel original packaging or equivalent packaging. In the absence of original or improper packaging, the warranty claim is at risk. Resulting transport damage will void the warranty claim.

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