ICV 4030 - CNC-Maschine mit CAN-Steuerung
Contents
1. DC motors control electronics servo amplifier IMD10 with CAN bus interface isel system module ISM10 with safety circuit module and CAN I O module 16 16 power supply 48VDC 500W as operating voltage for the servo amplifiers integrated control PC ISR20 with built in CAN interface PCI CAN ProNC RemoteWin and isyCAM2 5 software isel machines and controllers are concurrent with CE norms and marked accordingly Start up of all other machine parts or components for which CE safety regulations apply is prohibited until all respective requests are met isel Germany AG as the manufacturer cannot take over guarantee if you change the machine in any way The EMC test is valid only for the machine s original configuration ex works Basic knowledge in CNC technology and PC application such as Windows2000 or Windows XP are a prerequisite for your work with the ICV 4030 Please follow the instructions of this manual so that you can install the system properly work safely quickly and efficiently keep away danger from persons o and thus tap the full machine s potential For starting to work with this machine we recommend you to carry out the machining exercises of the ProNC and RemoteWin software We wish you a lot of success and pleasure for your work with the ICV 4030 Contents 1 CD PIC AMON nn EIERN ee 2 Security Advice Ener iaaa 2 1 Generalen a SR NR A E E EA EEA EEEE 2 2 2 AGEING Ol safety Panesar2. First startup At the first startup please conduct following steps To open the hood for the first time plug in the line cord and turn on the master switch The COVER button should be highlighted Only with that button highlighted will it be possible to open the hood For all following functions the emergency stop has to be unlocked Close the hood and turn on the power amplifiers by pressing the POWER button The button has to be highlighted You can call the software any time An error message will appear if the machine is not ready for operation power amplifiers not turned on The hood is locked during the machining process It can only be opened when the machine stands still the machine tool is turned off and the software allows the hood to be opend COVER button is highlighted To open the hood you have to press the COVER button After closing the hood it will be locked automatically To start the machine press again the START button Please refer to the software manual for all further information regarding the working with the software Key operated switch If you want to check the program the hood can be opened during operation when you switch the key operated switch to TEST test mode For this the machine tool must be turned off the program however will continue Make sure the tool is disengaged from the workpiece When the hood is open protection from moving parts of the machine is not guaranteed any more
3. do a reference move then open the hood and last turn off the machine To grease the Y axis move the T slot plate all the way to the front and unscrew it from the Y axis 6 screws Remove the plastic plug underneath Grease through the now visible lubricator nipple The guiding rails are accessible through the sealing lips To remove the cover plate of the Y axis release the fixing screws all around inicates in all drawings the access to the points to grease Ki Page 4 ICV 4030 CNC Compact Machine with CAN Controller As to lubricating the X axis move the slide to the left remove the plastic plug at the left side of the machine and grease through the now visible lubricator nipple Again the guiding rails are accessible through the sealing lips gt tos I av A A x With regard to the Z axis first remove the machine tool from its fixture then remove the three plugs and push the slide all the way down Through the two lateral openings some lubricant can be applied onto the guiding rails Behind the front opening you will find the lubricator nipple for the drive While the machine is turned off the slide can be moved manually Page 5 ICV 4030 CNC Compact Machine with CAN Controller 5 Starting Up 5 1 Prearrangements 5 1 1 Operating the integrated control PC For operating the control PC you need a screen with VGA attachment PS2 USB mo
4. 00W PFC Page 12 ICV 4030 CNC Compact Machine with CAN Controller 8 Malfunctions malfunction cause solution no power supply check mains supply mains plug machine cannot be multiple socket turned on master switch not turned on turn on broken fuse unplug mains plug and replace fuse see below POWER button out of function hood not closed close hood emergency stop not unlocked unlock emergency stop broken fuse unplug mains plug and replace fuse see below software does not work properly machine not turned on turn master switch on power amplifier not turned on turn on POWER button driver not installed install driver bad connection check cable connections machine tool does not work properly not enabled by the software do a system reset and a reference move rotary switch not on turn on machine tool traverse distances of axes not correct spindle pitch does not correspond to the software settings change the pitch value in the software refer to the control manual 9 Accessories The ICV 4030 CAN suitable accessories can be ordered accessorie item number dust collector 280110 9001 lighting for working area 280110 9004 graving pad 280120 9003 length calliper 280120 9010 spray cooling system 280220 9012 rotary unit e g 263013 0001 drilling and mi
5. Temporary malfunction no picture oft he connected display The connected WIBU USB dongle will no longer be detected gt The execution oft he user programm operating software ProNC Remote will be stopped with a error message gt After plug out and plug in oft he WIBU dongle you can start again the execution of the user programm Invalid loss of operating quality Data loss is not allowed Achange of the selected operating mode is not allowed No motion oft he axis after function failure Page 15 ICV 4030 CNC Compact Machine with CAN Controller 10 3 Service supply note Sender company customer ID number refrence person department telephone fax Address return delivery to invoice no quantity item number designation delivery note no serial number please add copy Cause for Complaint a commercial complaint O wrong delivery O wrong quantity O b technical complaint error description when does the error occur O constantly O temperature dependent O sporadically O after ___ minutes of running time has the item already been in use O not yet used O defect at starting up ___ months of use date signature Page 16 ICV 4030 CNC Compact Machine with CAN Controller Please take notice if you send back goods 1 Proof of purchase We require a copy of your purchase invoice or a delivery note to examine your warranty claim U
6. Therefore the key should only be used by authorized experts Machine tool The machine tool is directly wired and controlled by the software As well are the three other optional switching outputs which can be used to control additional devices refer to technical data The machine tool can be turned on only when the POWER button is highlighted the hood is closed and locked the rotary switch is ON and the software is controlling the machine Page 10 ICV 4030 CNC Compact Machine with CAN Controller 7 Technical Data 7 1 Mechanics ICV 4030 CAN Dimensions length x width x hight mm 780 x 835 x 810 Traversing range X Achse mm 395 Y Achse mm 300 Z Achse mm 100 Traverse speed X Y Z mm s gt 150 150 80 Admission hight mm 150 Clamping surface length x width mm 600 x 375 T slot grid mm 25 Weight approx Kg 150 Sound pressure level SPL db A lt 75 Power supply 230V 50Hz external fuse 16A Drive motor 120 Watt each Milling spindle motor depending on the type Fuse power input 2 x 10A time lag HBD Earthing corresponds to safety class 1 Page 11 ICV 4030 CNC Compact Machine with CAN Controller 7 1 Overview of electronic components an wenteengewatenn neneunu nen iSR20 breaking chopper frequency converter for milling spindle motor power power supply unit amplifier iMD 10 48VDC 10
7. ctive technical rules Do not use running water for cooling but a spray cooling system with a spray fog causing the cooling effect look accessories Drop formation and their gathering below the mounting table must be avoided Do not use spiritus as a coolant danger of explosion Regularly clean the machine from chips and dust deposits 2 2 Ageing of safety panes An examination conducted by the Verein Deutscher Werkzeugmaschinenfabriken e V VDW and the Employer s Liability Insurance Association has led to new discoveries about the ageing of polycarbonate beeing used for safety panes of machine tools Altough polycarbonate has proved perfectly well for that purpose these panes are losing their ability to protect against flying parts particulary under the influence of cutting fluids Polycarbonate panes that are protected from both sides against the effects of chips cutting fluids cleaning agents vapours etc provide the best resistibility on the long term We would like to point out that safety panes made from polycarbonate regularly have to be examined with respect to their protectability and if necessary be replaced Beeing the operator of such machines it is within your duty of care Such saftey panes in the future will be classified as wear parts Furthermore you are commited to indicate the respective matter to a possible buyer of the machine Despite these new discoveries polycarbonate as a material for safety panes w
8. isel From Components to Systems isel CNC Compact Machine ICV 4030 CAN User Manual isel Germany AG D 36124 Eichenzell B rgermeister Ebert Str 40 e 06659 981 0 06659 981 776 All information technical data and dimensions contained in this booklet correspond to the technical state at the moment of publication However possible misprints or mistakes cannot be ruled out We will appreciate all suggestions for improvement and error notes We would like to point out that all used soft and hardware names of the respective companies generally are subject to protection by brand trademark and patent law All rights reserved It is prohibited to process duplicate or reproduce this booklet partially or on the whole in any form print copy or other procedure without written permission of isel Germany AG This booklet has been translated from the original German version into English language It does not lay claim to completeness nor flawlessness In case of doubt the German original has validity Manufacturer isel Germany AG Burgermeister Ebert StraBe 40 D 36124 Eichenzell Tel 06659 981 0 Fax 06659 981 776 Email automation isel com http www isel com Art No Status 11 2011 ICV 4030 CNC machine with CAN control This manual contains the operating instructions for the ICV 4030 Router CAN machine control system ans its following components housing incl linear drive units with brush type
9. ithin the field of mechanical engineering still will be used for it s extremely high protectability We therefore can provide you any time with ready to be installed spare panes If required we can also offer you a retrofitkit as an additional protection on the operator s side in order to increase the required exchange intervals Page 2 ICV 4030 CNC Compact Machine with CAN Controller 3 Setting Up and Connecting The machine will be delivered ready assembled on a pallet The scope of delivery of the ICV 4030 includes housing including three linear drive units complete control electronics drilling and milling spindle with 3mm collet chuck chuck key size 22 clamping set hand lever stop rail 5mm Allan key triangular wrench to unlatch the hood switch line cord connecting line from PC to machine quad socket with lighted master switch ProNC or RemoteWin software optional CAD CAM software isy CAM optional the present user manual the required space for the machine amounts to its exterior dimensions and sufficient space for operating and setting the machine on the front side Allow some 10cm on the back side for the plugs The housing hood opens upwards total hight requirement is some 1 2 meters 805 7 dimensions and space requirement Keep the triangular wrench off machine above all during transportation The clamping set consists of a hand lever clamping mechanism and two stop rail
10. lling machine 500 W 420003 2050 drilling and milling machine 1050 W 420003 1050 clamping fixture stop rail milling cutter e g 690001 e g 290021 0175 e g 804110 5000 Make sure all accessories are correctly installed and follow applicable norms and safety regulations You will find installation and operating instructions for the accessories in the appendix For further information or order placements please turn to our technical consulting service Page 13 ICV 4030 CNC Compact Machine with CAN Controller 10 Appendix 10 1 Declaration of Conformity Declaration of Conformity corresponding Machinery Directive 2006 42 EU Annex II A The manufacturer isel Germany AG Burgermeister Ebert StraBe 40 D 36124 Eichenzell declares hereby that the following products Product designation isel compact CNC machine with safety hood Types ICV 4030 CAN Item No 280230 4405 conforms to the safety and health requirements of the Machinery Directive 2006 42 EU Annex I including those at the time of declaration current alterations The following harmonized standards have been applied EN ISO 12100 1 2003 Safety 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 13857 2008 Safety of machinery Safety distance
11. nless such a proof is enclosed the goods will be sent back at your costs without repair Additionally a fee will be charged 2 Error description If goods are sent to us without a detailed error description defect or for repair is not sufficient we will either do a diagnosis of errors at your costs or return the goods at your costs without repair Additionally a fee will be charged 3 Unjustified claims If your claim is not justified no error can be found an operator s error is likely the goods will be sent back at your costs without repair Additionally a fee will be charged 4 Packing For a return delivery to us we only will accept the original isel packing or an equivalent packing Your warranty claim will be put at risk if the packing is not original or improper Shipping damage resulting from that issue will invalidate the warranty claim 5 External products Products which were not purchased from us will be sent back at your costs without repair Additionally a fee will be charged 6 Shipping costs Shipping costs for return deliveries of products with valid warranty will be covered by isel Germany AG Costs for all others kinds of shipments are at the expense of the sender For organizational reasons not prepaid shipment of goods to us cannot be accepted 7 Terms of sales delivery and payment For the rest the terms of sales delivery and payment of isel Germany AG apply unaltered Page 17
12. ntroller 1 Application The ICV 4030 machine tool comes with three linear units which are controlled by electronics and software An additional unit rotary or linear is available This machine is designed for educational purpose and small series production It is designed for the use in dry rooms business premises living and school areas as well as laboratories and small factories at a max ambient temperature of 40 C 104 F It is suitable for milling drilling cutting engraving dosing measuring positioning and many other similar applications In accordance with above mentioned applications all sorts of suitable machining or measuring tools can be loaded Rraw materials such as light metal plastics wood glass and circuit board material are suitable for machining For safety reasons graphite material is not permitted explosion risk Nor are materials permitted that emit harmful gases when beeing processed The machine is prepared to hold a dust removal system which preferably should be used to remove dry dusts such as from wood circuit board material etc The machine s control system holds integrated the entire control and power electronics for three or 4 drive units Optional three 24V outputs and three 24V inputs are available to connect further electrical or electronical components ohmic consumer Using the software isyCAD CAM you can optionally pass on previousely generated CNC data directl
13. s including fixing material for the T slot plate Always make sure that the workpieces are well fixed Page 3 ICV 4030 CNC Compact Machine with CAN Controller 4 Cleansing Maintenance Before turning off the machine push the master switch to open the hood Afterwards it will not be possible Before cleansing and or maintenance of the machine always turn off the master switch and pull the mains plug in order to avoid the turning on by mistake Regularly clean the machine from all chips by using a brush or a vacuum cleaner do not apply compressed air This will preserve the mechanical parts from early wear It is advisable to regularly remove the covering plate of the Y axis underneath the T slot plate in order to remove possibly penetrated chips or dusts at bigger volumes of chip production and when the chips are very fine The sealing lips come with a Teflon component Particular maintenance is not required Clean the plastik washers with a non abrasive liquid cleaning agent The guiding rails as well as the drive shafts are provided with a long time greasing ex works Regrease them after 500 1000 working hours according to the applied load You may use common roller bearing grease for that purpose All guiding rails and shafts are greased with the soda soap grease GPO0 000F 20 according to DIN 51 502 In case you use oil lubricate regularly every 100 200 working hours In order to grease the drive shaft first
14. s 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 principles for design 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 Electrical equipment of machines Part 1 General requirements Also the following EU Directives have been applied EMC Directive 2004 108 EG Low Voltage Directive 2006 95 EG The technical documentation for this machine was created corresponding Annex VII Part A The manufacturer obligates to provide the technical documentation in electronic mode on demand of authorized governmental agency Representative for composition of technical documentation is Mr Helmut Danz Dermbach 18 01 2010 Werner Kister Managing board Page 14 ICV 4030 CNC Compact Machine with CAN Controller 10 2 Definition of the minimum operating quality The manufacturer isel Germany AG defines the minimum operationg quality for immunity tests for isel compact CNC machine with safety hood type ICV4030 CAN as follows Valid loss of operating quality
15. ssieeeeeeaeieieieisi ieinlarin ihn 2 3 Setting Up and Connecting a nennen 4 Cleansing Maintenance uunuuunnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 5 Stating UD e aaae aeaa aerarmea a namen 5 1 PrearrangemeNtSi ipnr aa a aa aoee 6 5 1 1 Operating the integrated control PC 6 5 1 2 Installing the software 6 5 1 3 Coordinate system 6 5 1 4 Bearbeitungsmaschine 7 5 1 5 Machine tool 7 6 Important Operating Instructions uuuuuuennnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 6 1 Operating device Sesani e aea a a aaa aa an 8 6 1 1 Switches and connections on the backside 6 1 2 Buttons and switches on the frontside 6 2 FISUSIAMUP nsien a a T AE E A 10 7 Technical Dalia E uaue have naeh aaa wa aa aa wann anna han aan awEn we 7 1 NCTA UGS 2RRRRRNRERRRERNERERATEREERERERRERRRARERENRRNERRRIEREESREIERAERERRNEURERERERIRSRENSRIRERERERURERER 11 7 1 Overview of electronic componentiS 24444440snnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn 12 8 Malf nctions EN 9 SACCOSSONIES a ee TO AD DOIN PFRORBRERFERNFRFFFRENERFRERFRERFEERENENPRERRUERFRERTTERERERENERFRENFEERTEFERNERORERFREEFEETTSFEORFERRERFREEEEEERER 10 1 Declaration Of Conformity ccccceeeeeeeceeeeeeeeeeeeeeeeeeeceaeeeeeeeeeeeeeeeeennaeeeeeeees 14 10 2 Definition of the minimum operating quality cceeeeeeeeeeeeeeeeteeeeeeeees 15 10 3 Service supply note eee 16 ICV 4030 CNC Compact Machine with CAN Co
16. switch disconnect the line cord from the distribution box release the outer screws 3 just release not unscrew and take out downwards the machine with its fixture and the T nuts Many other tools measuring instruments laser or other devices can be mounted onto the T slot plate of the Z axis by using the appropriate fixtures Use the distribution box of the Z axis for electrical connection When you mount the machine tool or other tools you have to adjust the fixture again parallel to the XY plane Page 7 ICV 4030 CNC Compact Machine with CAN Controller 6 Important Operating Instructions 6 1 Operating devices 6 1 1 Switches and connections on the backside 2 3 4 number designation description 1 VGA connector Connector 15 pin VGA monitor 2 PS 2 Mouse Connector for PS 2 Mouse 4 PS 2 keyboard Connector for PS 2 keyboard 4 Power supply connector 230V AC power supply connector with main switch and fuses 2 x 10A time lag HBD 6 1 2 Buttons and switches on the frontside ICV 4030 CNC Compact Machine with CAN Controller Operating devices to control the machine number designation description 1 Emergency Stop button Turns off the power supply for the motor power amplifier and the working spindle 2 Power ON button Turns on the power supply for the power amplifiers 3 Fault indicator The fault indicator indicates an error within the safety circuit 4 Star
17. t button Starts the processing of the current NC program or continues an interrupted processing 5 amp t nikufi n Interrupts the processing of the current NC program The repeated pressing of the Stop button will abort p the processing not for all control configurations valid This button is used to open the hood if existing The hood may only be opened when the Cover button is highlighted axes must be in HOME position or operating mode switch is set to Test 6 Cover button Note To open the hood with the COVER button press the hood shortly down therewith the tongue of the Schmersal switch is released After that push the hood upstairs Press this button in order to move the axes when the machine is in setup mode and the hood is open 7 ACK Acknowledge button Use this key operated switch to switch between automatic and setup mode In automatic mode the hood 8 operating mode switch resp door can only be opened when all axes are in their HOME position In setup mode the hood can be opened and pushing the ACK button axes can be moved Operating devices for the control PC number designation description 9 Power button Turns on the integrated control PC 10 Power LED Operation indicator of the control PC 11 HDD LED Indicator for access to the hard disk 12 USB slots USB 2 0 slots for USB devices USB Stick WIBU etc Page 9 ICV 4030 CNC Compact Machine with CAN Controller 6 2
18. use e PS2 USB keyboard 5 1 2 Installing the software For programming and running the control system of the machine the ProNC or RemoteWin software is needed In case the included software has not yet been installed and adjusted in the factory please refer to the notes regarding software installation on the installation CD 5 1 3 Coordinate system The machine s coordinate system is defined as shown in the picture below You can freely select and move the starting point PO on the workpiece through the software However the machine s reference point machine zero point from the factory is set to the front Y left X and top Z ofthe machine stickers on the machine identify the axes Page 6 ICV 4030 CNC Compact Machine with CAN Controller 5 1 4 Bearbeitungsmaschine 5 1 5 Machine tool The collet chuck 4 of the standard machine tool can hold different tools with a shank diameter up to max 6 35mm standard 3 mm other refer to accessories Use two spanners size 22 for changing the collet chuck Power supply for the machine tool will be enabled by the software The speed of revolutions can be set manually by the tnumb wheel 1 To dismount the machine tool turn off the main switch of the ICV 4030 disconnect the line cord from the distribution box release the locking screw 2 and take the machine tool out of its fixture To dismount the machine tool together with its fixture turn off the main
19. y into the machine through the control software ProNC RemoteWin and thus have the work piece beeing machined Page 1 ICV 4030 CNC Compact Machine with CAN Controller 2 Security Advice 2 1 General Do not operate the machine in a potentially explosive atmosphere The machine is fully enclosed The housing protects you from moving tools reduces the noise level and holds back chips The hood is locked during operation and cannot be opened Please do not change or remove this mechanism The safety circuit includes soft and hardware Therefore the machine will only work with the appropriate and proper working control core on the circuit board only type 2 and 3 In case of emergency you will find an emergency stop switch on the front side of your machine It will interrupt power supply for the power amplifier However communication between software and the machine will remain active for error diagnostics Because of an increased risk when operating the machine in test mode only briefed experts may make use of the key switch Please keep the spare key shut away All 230V consumers are connected in a unipolar way you have to assume that they are not necessarily free from tension when switched off Please provide sufficient ventilation to remove dusts and gases resulting from the processing of the material If you want to use a laser for measuring application only use appropriate class 2 devices and follow the respe
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