isel automation GFV 44/33 Operating manual

GFV 142/102
GFV 44/33
GFV 44/73
GFV 68/52
GFV 102/62
GFV 142/102
GFV 142/162
GFV 142/232
®
Operating and Maintenance Instruction
B.2745xx/2002.04/E
Order-number: _________________
Serial-number:__________________
isel flat bed installation

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isel flat bed installation GFV
On this Manual
Various symbols are used in this Manual to quickly provide you with brief information.
Danger Caution Note Example Additional
Information
© iselautomation GmbH&Co.KG
All rights reserved.
Despite all care, printing errors and mistakes cannot be ruled out completely.
Suggestions for improvement and notes on errors are always welcomed.
isel machines and controllers are CE compliant and are marked accordingly.
Any other machine parts and components subject to the CE safety guidelines may not be
commissioned unless all relevent standards are fulfilled.
iselautomation shall not accept any liability for any modifications on the device by the
customer.
The limit values specified in the Certificate of Conformity only apply to the original
configuration from works.
Manufacturer:Co. iselautomation GmbH & Co.KG
Bürgermeister-Ebert-Straße 40
D-36124 Eichenzell
Fax:[phone]
E-Mail: [email protected]
http://www.isel.com

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Contents
1 Introduction ...................................................................................................................... .4
2 Intended use ..................................................................................................................... .5
3 Safety notes ...................................................................................................................... .6
4 Scope of delivery ...............................................................................................................7
5 Setting up and connection ............................................................................................... .8
5.1 Spacialrequirements .............................................................................................................. .8
5.2 Transportation ........................................................................................................................ .9
5.3 Setting-up .............................................................................................................................. .9
5.4 Enclosure............................................................................................................................. .10
5.5 Wiring................................................................................................................................... .10
6 Commissioning.............................................................................................................. .11
6.1 Preliminary notes ................................................................................................................ .11
6.2 Cover interlocking ............................................................................................................... .12
6.3 Operating console ............................................................................................................... .13
6.4 Activating the software ........................................................................................................ .14
6.5 Operating modes................................................................................................................. .15
7 Accessories ................................................................................................................... .16
8 Cleaning/maintenance .................................................................................................. .18
9 Interferences ................................................................................................................. .20
10 Technical data ................................................................................................................ .21
11 Appendix...........................................................................................................................22
Certificateof conformity

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isel flat bed installation GFV
1 Introduction
The isel GFV Flat Bed Machining Systems are proven CNC machines that offer an
abundance of possibilities for three-dimensional processing of work pieces.
The machines are built and equipped in various sizes and designs. Tailored standard
sections and drive elements that are combined according to requirements form the basis.
Therefore, the external appearance of the machines can be very diverse.
The internal life, therefore the substantial set-up of mechanics and the electrical control is
common to all machines. Before delivery, every individual machine is tested and run-in in
detail for many hours.
As a requirement for your work you need basic knowledge in CNC technology and PC
application, a computer, and the control electronic, an electrical outlet and some creativity.
Please take note of this short instruction now so that you
· set up the installation properly,
· can work surely, quickly and effectively,
· keep away dangers of persons
· and thus exploit the full potential.
The explanations in this instruction are based on a standard scope of delivery with which
the machine is ready for operation. You can simply skip explanations that do not concern
your machine (e.g. in case of accessories and software).
Please note the additional reference manuals and instructions for the installation and
commissioning of software and accessories.
We wish you much success and pleasure for the future work with the flat bed installation.

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2 Intended use
The flat bed equipment is a machine tool with several linear axes and a rotary axis. Motors
and switches of the driving axes can be driven via computer. By default*, the complete
control and power electronics of all axes are located in the external 19" Penguin II data
terminal.
- The CNCmachine isdesigned foruse indry areas,businessareas, schools,in laboratories,
and industrial plants (min 10 °C / max. 40 °C ).
- The machine is suitable for milling, drilling, cutting, engraving, dosing, measuring,
positioning and many similar uses.
- You can attach the most different suitable machining tools or measuring instruments,
appropriate to the above above-mentioned applications.
- Suitable processing materials are aluminium, PVC, wood, glass, printed circuit board
materials a. o.
Materialsreleasinggasesthatendanger health are notpermittedforprocessing.
-The machine isprepared foran exhaust system.This exhaustis preferably suitedfor dry
dusts (wood, printed circuit boards etc.)
* the systems are customer specifically set-up.

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3 Safety notes
• The machine may not be operated in an explosive atmosphere.
• The machine is encased all around. The enclosure protects you against moving tools,
decreases the operating noise level, and restrains the chips.
During processing, the hood is bolted and can not be opened.
You may neither remove nor change this safety device.
• Alwaysensurethattheworkpieces areproperlysecured.
• For cases of emergency, you find an Emergency-Stop switch on the service console
and at the power unit; it interrupts the voltage supply for the power electronics and to
the main spindle drive.
• Expert and trained personnel may only handle the key-operated switch since an
increased injury danger exists in test operation.
Please keep the replacement key under lock and key.
• The persons, who control the machines, must be 18 years old!
Allpersons, particularly under eighteen years,must beconstantly supervised by the
training!
• Ensure sufficient ventilation when machining material releasing dust or gas.
• No liquid water may be used for cooling but only a spraying/cooling device with which a
water fog causes the cooling action (see accessory). No drops may be formed and flow
under the bottom plate.

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4 Scope of delivery
The standard scope of delivery of the flat bed installations includs:
• Aluminum basic rack including
- enclosure
- suction tube and connection adapter
• Driving axes including limit switches
• Operating console
• Triangular key for unlocking the hood switch
• Penguin II 19" data terminal including
- 14" or 17" monitor
- keyboard
- power cable
- cable tubing with penguin <—> connecting cables
- power unit
- CNC servo controller
- safety circuit module (SK module) with power supply unit
• ISELDRV machine driver
• REMOTE machining software
• and this operating and maintenance instruction
Please, refer to you delivery note for the precise scope of accessories of your machine.

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> 500 mm
> 150 mm
X
GFV
5 Setting up and connection
5.1 Spacial requirements
The spacial requirements of the machine are limited to the external dimensions of the
machine and the Penguin and sufficient free space is available in front of or at the side of
the machine in order to operate and install it. Normally, the cover of the enclosure turns
upwards. Thus, you must keep approx. 50 to 60 cm of free space in addition.
Dimensions and spacial requirements
Model B T H X
GFV 44/33 760 1010 1750 2300
GFV 44/73 1160 1010 1750 2300
GFV 68/52 1410 1260 1880 2480
GFV 102/62 1810 1410 1880 2480
GFV 142/102 2210 1810 1880 2480
GFV 142/162 2210 2410 1880 2480
GFV 142/232 2210 3110 1880 2480
Penguin without feet 550 675 1380 -
Dimensions in [mm]
Consider the total overall height (X) with the hood opened.
In case of the special sizes with increased portal, the enclosure increases by approx. 300
mm (H + 300 and X. + 300) by default.
Penguin
(Control
cabinet)

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5.2 Transportation
Remove the transport safeguards at the rack feet.
Use only suitable lifting devices (fork-lift truck, lifting truck, see figure). Only raise the
machine from below. Do not pull it up at the cover.
During a later transportation, please ensure that the voltage supply and connection cables are
not damaged. Remove all cables before any transportation or transport machine and penguin
simultaneously, e. g. on one pallet.
Above all, always keep the three triagular key outside of the machine during
transport.
5.3 Setting-up
Ex works, the worktable and all axes are exactly aligned right-angled.
Never loosen the fastenings of the axes or the angular brackets. Otherwise, you must re-
adjust the axes again.

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SW 13
Place the machine onto a plane and solid surface. You
canbalancesmallunevennessesofthefloorusingthe
feet.
To level the machine accuratetly, you need a spirit
level with a minimal precision of 0,5 mm/m.
1. Put the spirit level onto the machine table and adjust the feet until the machine is
leveled at least 0,5 mm/m lengthwise and crosswise.
2. Fix the height of the maschine feet with the lock nut.
5.4 Enclosure
For repairs or extensive maintenance
and cleaning tasks, the enclosure can
be unscrewed separately. Every
column is fixed by a threaded rod in
the lower part. From the top, loosen
the two nuts and the threaded rod. If
you pull out the rod, the cover can be
completely removed as one part (up
to the size of 102/62). At larger
machines, the cover consists of
several parts.
Without cover, the machine must never be put into operation.
5.5 Wiring
The CNC machine is driven by an IBM compatible computer and power electronics for the
motors. Integrated into one control cabinet (Penguin II), the controller is completety wired
and connected to the machine.
You find a detailed overview of the wiring in the instruction of the CNC servo-controller.
Connect the power cable to the control cabinet (Penguin II) only if the machine is ready for
commissioning.
Route all cables exclusively through the cable tube of the penguin to the machine and
ensure that both ends are always screwed on firmly (strain relief).
bottom top

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P
0
6 Commissioning
6.1 Preliminary notes
This figure present an overview of the electronic components in the Penguin.
ÀÀ
ÀÀ
ÀEmergency-Stop
(at the operating console)
ÁÁ
ÁÁ
ÁMonitor
ÂÂ
ÂÂ
ÂKeyboard
ÃÃ
ÃÃ
ÃControl computer
ÄÄ
ÄÄ
ÄPower unit
ÅÅ
ÅÅ
ÅBlank sheet metal
ÆÆ
ÆÆ
ÆMouse interface
ÇÇ
ÇÇ
ÇMain switch (on the rear side)
ÈÈ
ÈÈ
ÈSK module (internal)
Coordinate system
The coordinate system of the
machine is defined as shown
in the figure. Nevertheless, you
can select the P0 workpiece
zero point unrestrictedly via
software (offset).
Stickers on the machine identify the axes.
Please, read the manual of the iseldrv.exe driver if you must modify the configuration of
the coordinates. Contact our technical service in case of questions.
Reference point and home position
Ex works, the reference point of the machine (machine
zero point) and the home position are pre-set to the
corner on the upper left at the back (seen from the front).
This location of the home position is signaled to the
controller using an electromagnetic switch contact. As a
pulse generator, the magnet is fixed to the enclosure.
Without havng a physical contact, the reading contact on
the Z-axis recognizes the home position if it recognizes
the magnetic pulse.

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Memory
For the computer to work error-free, approx. 600 Kbytes of conventional main memory and
approx. 140 kilobytes of high memory should be available.
You can check your memory when calling the Memmaker DOS program.
There, enter: EMS —> no and Search high memory area.
Thus, sufficient memory should be available.
Workpiece clamping
Use only suitable secure jigs if you set up your machine.
Always pay attention to a fixed seating of the workpieces.
6.2 Cover interlocking
- Basically, the machine must be in the home position (reference point) in order to open the
cover. An exception is if the machine is in the test mode or you bypassed the safety
function using the triangular key.
- The spindle can turn only if the cover is interlocked (exception in the TEST mode).
- For special occasions (if a switch is defective or in case of a power failure etc.), you can
open the cover bolting device manually using the triangular key.
1. Power-down the machine.
2. Without using excessive force, turn the
triangular key half a revolution to the left and
open the cover.
You may not operate
the machine in this state.
The processing machine remains de-
energized.
3. Turn the triangular key again to the right.

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1
6
2
7
3
4
5
6.3 Operating console
The operation of the GFV is performed using a movable operating console. It helps to install
themachineinanuser-friendlymanner.
ÀÀ
ÀÀ
ÀEmergency-Stop
... removes power from the drive controller.
Unlatching by turning to the right.
ÁÁ
ÁÁ
ÁPOWER
... to switch on the power electronics.
The power stage can only be switched on if
Emergency-Stop is unlatched and the cover is closed.
ÂÂ
ÂÂ
ÂKey-operated switch
... using the key you can select between the AUTO or
TEST operation modes.
AUTO = machining mode
TEST = debug mode
In debug mode, you can open the cover at any time.
ÃÃ
ÃÃ
ÃSTART
... continues a stopped movement.
The machine continues exactly at the place where it was interrupted by the STOP key
if machining was not completed via software.
ÄÄ
ÄÄ
ÄSTOP
... stops the current program immediately and remains at the present (program)
location. The machine remains powered-up and the cover is locked.
ÅÅ
ÅÅ
ÅACKNOWN switch
... in the TEST operation mode and while moving the axes, the push-button must be
activated for as long as the cover is opened.
The SK module removes power from the drive controller (power module) if the key is
released with the cover being open.
ÆÆ
ÆÆ
ÆCOVER push-button
... causes the deactivation of the safety locking device if pressed and allows thus the
opening of the cover provided that all corresponding conditions of the SK module are
met. The pushbutton is only operable if it lights up.

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isel flat bed installation GFV
6.4 Activating the software
The iseldrv.exe machine driver is already installed (DOS) on the control computer (CNC
servo controller). You only have to load it before any start of the machining software.
It is recommended to load the driver using the drv.bat batch file. (You activate the program
and inform the computer where the default settings are stored for your machine.) If the file
does not exist yet you can easily generate it yourself (edit drv.bat).
The content of the batch file is: LH \servo\iseldrv \servo\servo.ini
Enter ’drv’ and (return). The driver prompts you to power-up the machine (press the
POWER button).
Next, start the machining software (REMOTE, ISY etc.) provided that the programs are
already installed.
As a example: Start the REMOTE program by changing to the c:\remote
directory and enter ‘remote’ .
Alternatively, you can also use a batch file
(refer to the REMOTE machining examples manual).
Please, refer to the corresponding manuals and/or readme files on the installation floppy
disks for further notes on the software.
You find all descriptions regarding the handling of the software in the enclosed manuals.
The software contained in your scope of delivery, e.g. ISY or ProLeiSys, is stored on a
CD or floppy disk. The manuals are also included.

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isel-flat bed installation GFV
6.5 Operating modes
- Auto
In the AUTO operating mode, a loaded program is automatically executed and thus your
workpieces are machined. During processing, the cover is locked. You can only open the
cover after the machine has reached the HOME position and the machine (spindle) is
switched off.
Press the COVER key before opening the cover. After closing, the cover is automatically
locked again.
- Test
For testing and checking, you can run the machining program with the cover open if you
turn the key-operated switch to the right (test mode). Now, the program is only processed
for the time the ACKNOWN key is pressed.
The test operation has no influence on the machine, it remains powered-up.
Injury hazard!
This key may only be used by expert and authorized personnel since no protection
against moving machine elements is guaranteed in the test operation after opening
the cover.

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7 Accessories
You can order the following matching accessories for the GFV:
• Clamping set (bolt lever, 2 dead stop rails, hollow wrenches)
• Supplementary mounting material for the T-slot plate
• Supplementary collets for the spindle:
1 to 5 mm in 0,5 mm steps, 6 mm and 1/8"
• Tool kit
• Three different tool changers with high-frequency spindle (MA 2.11)
including software, option: length sensor
• Rotary axes
• MA main spindle drivers, collets to 6,35 mm
Spindle motor MA 2.05 + frequency converter, 650 W, 0 - 20,000 r.p.m.
Spindle motor MA 4.05 + frequency converter, 400 W, 0 - 6,000 r.p.m.
• MA main spindle drivers, collets up to 10 mm
Spindle motor MA2.11 + frequency converter, 1,100 W, 0 - 15,000 r.p.m.
Spindle motor MA 4.11 + frequency converter, 1,100 W, 0 - 6,000 r.p.m.
• Kress processing machine, 900 W, 8 000 - 20 000 r.p.m.
• Exhaust system
• Industry vacuum cleaner
• Engraving spindle
• Engraving basis
• Spraying/cooling device, coolants
• Grease gun
• 19" Penguin II data terminal including 17" monitor, mains cable and
cable tubing with connecting cables: Penguin <--> machine
• Complete control electronics (CNC servo controller + power unit)
• Interpreter for isel REMOTE intermediate format
• PRO-PAL CNC software
• PRO-DIN CNC software
• ProLeiSys CNC software (isolation milling)
• ISY CAD/CAM software
Pay attention to an expert mounting with every accessory and consider the valid standards
and safety regulations.
For further information and/or purchase orders please contact
Technicalconsultation phone [phone],-489,-215
fax [phone].

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isel-flat bed installation GFV
Exhaustsystem
For an exhaust system, a suction tube with a
connecting piece for the standard diameters 32, 35
and 38 mm is pre-installed. Connect a vacuum
cleaner here.
The other end of the suction tube ends at the Z-
axis. You can connect a exhausting device here.
For the Kress processing machine (900 W), an
exhaust system is available.
Spraying/cooling device
The spraying/cooling device is pre-installed ex works. You need only to apply the
refrigerant. The compressed air is enabled by the maintenance unit for compressed air.
The entrance air pressure of the maintenance unit can be 4 to 10 bars. The maximum
permissible pressure of the spraying device is 7 bars. Partially, the working pressure is far
below.
Tool changer
The tool changer (with 4, 5 and/or 10 tool
positions) is connected ex works and ready for
immediate use.
The working pressure is approx. 8 bars.
Compressed air must be supplied via the
maintenance unit.
Consider the ITC commissioning manual
(isel tool change).
The length sensor (optional) for the tool
changer is mounted at the front to the right
beside the clamping plate.

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8 Cleaning/maintenance
Turn off the mains switch before every cleaning and maintenance operation and pull the
power plug in order to prevent the machine from starting inadvertently.
- Clean the machine regularly with a broom or vacuum cleaner to remove all chips (no
compressed air). That protects the mechanics of the machine against early wear.
- The sealing lips contain a Teflon component and do not require special servicing.
- Clean the perspex windows with a non-abrasive liquid cleaner.
- A compressed air system can constantly blow air into axes to essentially prevent dirt
getting into the axes.
You must, however, provide a compressed air system for this purpose. The compressed
air hose is attached to one of the drillholes that also serves as access to a lubricating
nipple.
- Ex works, the guideways and drive shafts are equipped with long-term lubrication.
Depending on the strain put on them, you should lubricate the guideways and drive shafts
approx. every 500 - 1,000 operating hours. Use normal roller bearing grease for this
purpose.
If you are lubricating with oil then do this every 100 - 200 operating hours.
In the works, the guideways and shafts are lubricated with the sodium soap grease
GP00/000F-20 according to DIN 51 502.
Do not lubricate to much at one time. The shafts and the steel rails must not be flooded
with lubricant.
If you want to lubricate, first of all run a reference cycle, open the cover and then turn off
the machine at that point.
- If you need to undertake extensive maintenance it is easier to remove the enclosure.
Do not misuse this possibility for normal operation because you would be abusing all of
the built-in safety measures.

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S
S
S
S
S
S
S
S
You will find two black plastic stoppers on the side of the
Z-axis. Beneath these, the lubricating nipples are to be seen
when the slide is located at the upper or lower end limiting
switch position.
Remove the stoppers, push or move the slide to the end
limiting switch position* and lubricate through the now visible
lubricating nipples (S) (two above, two below).
S
in all drawings, this shows a lubricating nipple or the
access to the lubricating points.
The Y-axis is built up as the Z-axis.
Grease on the right and on the left
side through the lubricating
nipples.
If you loosen the incoming feed
tubes to the right in the cable
duct, in order to obtain better
access to the lubricating nipple,
you must also tighten them up
again afterwards.
With the X-axis, the linear driving
mechanism is located on the work
top.
Remove the plastic stoppers on
the inside and lubricate in the
same way as the other axes
(once each in the front and at the
back).
The angular gears below the work top are maintenance-free.
*If the machine is off, you can move the slides of the Y- and Z-axis manually to
the limit switches.

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isel flat bed installation GFV
9 Interferences
Defect Cause Solution
System can not be switched on Mains connection is not available Check circuit
Plug in AC power connector
Main switch not switched on Switch on main switch
POWER push-button does not work Cover not closed Close cover
Emergency stop not unlatched Unlatch Emergency stop
Driving motor does not react No voltage supply of the Check fuse in power block
power stage, fuse is defective Check fuse in power output stage
Temperature protection of the Check fan in the controller
power stage is active Check slots in the bottom plate
(LED Temp lights)
Power stage is defective Change power stage (send in)
Connector has loosened Check connector at the controller
output and at the motor
Cable break Replace cable
Processing machine (spindle) Not enabled by the software Enable via software does not work
Rotary switch at that machine is Switch on the machine
off(Kress)
Falsedriverinstalled Usematchingdriver
Machine is in home position Movemachine intowork-space
Cover bolting device is open Close cover bolting device with the
three edge key
Safety device in the converter AC power connectors draw
is defective Refresh safety device