Isel ICP 3020 User manual

isel Germany AG Bürgermeister-Ebert-Straße 40 D-36124 Eichenzell Tel.: [phone] Fax: -776
Operating Instruction
CNC compact machinery
type
model
ICP iMC-P
ICP 3020, ICP 4030

ICP 3020 / ICP 4030 iMC-P
Seite 1
About this manual
Used shortcuts
MD
Machinery directive 2006/42/EC
Used symbols
You will find different symbols in this manual that signalizes important information/ facts and
danger.
Warning!
This symbol indicates dangers that cause damages for person’s health,
physical injury or death.
Warning! Dangerous voltage!
Warning of danger from 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 the machine
/ in the housing of the machine, make sure to read carefully the
safety instructions in this manual. (Chapter Fehler! Verweisquelle
onnte nicht gefunden werden.).

ICP 3020 / ICP 4030 iMC-P Operating instruction
Seite 2
Copyright
isel Germany AG, 2009
All rights reserved.
Despite all care, printing errors and mistakes cannot be excluded.
For suggestions and information on errors, we are grateful.
CE mark for (completed) CNC machinery:
isel CNC machinery are CE compliant and marked accordingly.
For these machines is the CE declaration of conformity valid.
No CE mark for partly completed machinery:
Partly completed machinery (definition from EC machinery directive 2006/42/EC) has no
CE mark.
For partly completed machinery the declaration of incorporation (referred to in Annex II, part
1, section B) is valid.
For all other machinery parts and components, be applied to the CE safety directives, initial
operation are prohibited until all appropriate requirements are met.
The company isel Germany AG assumes no responsibility or liability if you make any
changes without the consent of the manufacturer of the machine that affect the CE-
conformity of the machine.
The EMC test is valid only for the controller’s original configuration ex works, i.e. the
delivery state.
Manufacturer: isel Germany AG
Bürgermeister-Ebert-Straße 40
D-36124 Eichenzell
Tel: [phone]
Fax: [phone]
e-mail: [email protected]
http://www.isel-germany.com
Item-no.: 970280 BE016
(translation of operation instruction in German language)
State: 02/2014
Technical changes reserved.
Latest operating instructions and manuals for download, visit:
www.isel-data.de/manuals

ICP 3020 / ICP 4030 iMC-P Operating instruction
Seite 3
Table of contents
1Introduction................................................................................................................... 5
2Intended use and reasonably foreseeable misuse .................................................... 6
3Safety instructions........................................................................................................ 8
3.1 Occupational safety......................................................................................9
3.2 Operators .....................................................................................................9
4Delivery status from the factory (quality safety)...................................................... 10
5Installation and connection of the CNC machine..................................................... 11
5.1 Dimensions and space requirement........................................................... 11
5.2 Transport of the CNC machine...................................................................12
5.3 Installation of the CNC machine................................................................. 12
5.4 Coordinate system and reference point...................................................... 13
5.5 Tooling machine......................................................................................... 13
5.5.1 Enclosure with safety interlock 14
6Assembly 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
6.4.2 Connectors 22
6.5 Adjusting the stepper motor power amplifiers............................................. 27
7Installation and initial operation................................................................................ 30
7.1 Safety notes................................................................................................ 30
7.2 Preparation................................................................................................. 30
7.2.1 Connections 30
7.3 Software installation ................................................................................... 31
7.4 Operation modes........................................................................................ 32
7.4.1 Using the ICP 3020 / ICP 4030 in CNC mode 32

ICP 3020 / ICP 4030 iMC-P Operating instruction
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7.4.3 Using the ICP 3020 / 4030 in DNC mode 34
8Maintenance................................................................................................................ 35
8.1 Cleaning the machine................................................................................. 35
8.2 Lubrication..................................................................................................35
9Faults ........................................................................................................................... 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

ICP 3020 / ICP 4030 iMC-P Operating instruction
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1 Introduction
This manual contains the operation instruction for machinery of type ICP with iMC-P
stepper motor control.
The machine is delivered fully assembled on a pallet. In the scope of delivery of the ICP
3020 / 4030 is included:
 machine case inclusive :
othree drive axles with ball screw spindle 16 x 10mm, 5mm, 4mm or 2,5mm,
2 phase stepper motors with two limit switches
oprotection hood with solenoid interlock
stepper motor control behind the backplane of the machine inclusive:
onet input filter with main switch and fuses
o2 phase stepper motor power amplifiers up to 4 axes with 4A rated current
obase board with processor (core module)
osecurity circuit module (SC module)
o48V and 24V power supply unit
oFunction keys and emergency stop switch on the machine front side
onet cable
ocommunication cable
drilling / milling machine with 3 mm collet
 wrench for collet, wrench opening 22
clamping set (lever, stop rails,5mm hexagon wrench )
 triangular wrench to unlock the protection hood
4-fold power strip with lighted main switch
Remote as control software (optional: ProNC)
CAD/CAM software isyCAD/CAM 2.5 Plus (optional)
operating instruction
Please note this manual that you
•install and do commissioning of CNC machine correctly
•can work safety, fast and effectively
•keep away danger from persons and the equipment
•can fully profit from the capabilities of CNC machine.

ICP 3020 / ICP 4030 iMC-P Operating instruction
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2 Intended use and reasonably foreseeable misuse
Isel CNC machinery of type ICP are CNC controlled machinery with more than one linear
axis resp. one or two optional rotation axis. The motor power amplifiers will be driven via a
PC based stepper-motor-control. All control and power electronics for the axis is mounted in
a control cabinet.
Differences between CNC machine and CNC base machine:
isel-CNC-machine:
In the new, at 29.12.2009 legally binding machine directive 2006/42/EC, is the term
“machinery” defined as follows (quote from EC directive, article 2, letter a):
„machinery“
an assembly, fitted with or intended to be fitted with a drive system other than directly applied human or
animal effort, consisting of linked parts or components, at least one of which moves, and which are joined
together for a specific application.
Each isel-CNC-machine delivered with a tool (e.g. milling or engraving spindle, metering
device, measuring device like CCD camera or triangulation laser, water jet nozzle, plasma
burner), is for the purpose of the directive 2006/42/EC a machine, because she was
manufactured for a specific purpose 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 assessment for
the CNC-machines. CNC-machines will be delivered with a machinery enclosure.
isel-CNC-base-machine:
In the new, at 29.12.2009 legally binding machine directive 2006/42/EC is the term “partly
completed machinery”defined as follows (quote from EC directive, article 2, letter g):
„partly completed machinery”

An assembly which is almost machinery but which cannot in itself perform a specific
application. A drive system is partly completed machinery. Partly completed machinery
is only intended to be incorporated into or assembled with other machinery or other
partly completed machinery or equipment, thereby forming machinery to which this
Directive applies;
Each isel-CNC-base-machine delivered without a tool and therefore not for a specific
application is for the purpose of the directive 2006/42/EC a partly completed machine.
The CNC-machine / CNC-base-machine is used for work in dry rooms (workshops,
laboratories) and industrial firms (max. ambient temperature: 40°C)

ICP 3020 / ICP 4030 iMC-P Operating instruction
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CNC-machine:
oThe CNC-machine (complete machine) is according to the type mounted on the
machine tool appropriately used. That is, the concrete tool of the CNC machine
specifies the intended use of the machine within the meaning of the Machinery
Directive (Annex I, Section 1.1.2). Under this premise, the CNC-machine is
suitable for milling, drilling, cutting, engraving, metering, measuring or water jet
cutting. The CNC-machine is not suitable for graphite machining.
oAppropriate processing materials are light metals, plastics, wood, glass, platinum
materials, etc.
oNot permitted are materials which produces during processing harmful gases
oThe CNC-machine is prepared for an extraction unit device. This extraction unit is
preferably suitable for dry dust (wood dust, fibreglass / fibreglass dust, platinum
dust, etc.).
The CNC base machine (partly completed machine) can be added by you as the buyer
of the base-machine with a variety of appropriate processing tools to a CNC-machine
(complete machine) in compliance with the requirements of the machinery directive. You
are responsible for CE certification if you use the machine itself resp. sell (bring to
market). The CE certification also includes the legally required identification of a safe
machine by the CE mark.
CNC-machinery for milling processes:
oThe CNC-milling-machines are designed for milling/drilling of the following
materials: aluminium, copper, brass, plastics (e.g. GRP / fibreglass), wood
oThe processing of magnesium is prohibited because of fire.
oDuring the processing of steel / stainless steel only engraving or a processing
with low cutting forces is possible.
oIt 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 corresponding processing speed for the material.
oAll machines are designed for milling spindles (spindle machining, induction
motor) with a maximum of 3 kW drive power.
oCutters and drills may be used up to a maximum shaft diameter of 12 mm.
oThe tools form cutters and conical formers for timber industry may be used up to
a maximum cutting diameter of 45mm and a shaft diameter of 12 mm.
The rapid traverse velocity should not exceed the values of 150mm/sec till 200mm/sec
depending on the machine size.
The feed rate of the processing tool in the material must be determined technologically
and should be smaller than the rapid traverse speed.
For the secure clamping of the tools in the tool holder, the user is responsible.
To the reasonably foreseeable misuse belongs the operation of the machine by two
persons. It is prohibited that one person executes a motion of the axis of the CNC
machine via software (manual move or program start) or by pressing the START button
on the operating console / CNC operation panel and another person is touching into the
machines workspace or do work in another way when the safety door is open and an
axis movement is going on.
You are not allowed to manipulate the locking of the safety door.

ICP 3020 / ICP 4030 iMC-P Operating instruction
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3 Safety instructions
Do not operate the machine in a potentially explosive atmosphere
The machine is fully enclosed.
The transparent panes (material: polycarbonate) mounted in the machine
frame resp. in the door ensure during operation of the machine (setup or
working process) protection against moving machine parts as well as
eventually thrown work piece fragments from the work area.
The housing protects you from moving tools, reduces the noise level and
holds back chips.
The door is locked during operation and cannot be opened (safety
solenoid interlock). Please do not change or remove this mechanism.
You are not allowed to put a CE marked CNC machine into operation if
the enclosure is not complete, intact or the polycarbonate panes are
damaged.
The delivered CNC base machinery without safety door / hood are partly
completed machinery for the purpose of the directive 2006/42/EC. They are
delivered without a CE marking. It applies the declaration of incorporation
and the assembly instruction.
As the operator 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 clamped. The use of save and
suitable parts / devices for work piece clamping is one of the tasks of the
operator of the CNC machine. Unsuitable not safe devices for work piece
clamping can cause unfasten of work piece from device during operation.
This can result in heavy damage and accidents with fatality or personal
damages. In this case can also damages of tool, work piece, clamping
device or other parts of the machine occur.
In case of emergency, you will find an emergency HALT switch on your
hand control unit / CNC control panel. It will interrupt power supply for the
power electronics (motor power amplifiers) and frequency inverter for main
spindle drive (STOP category 0 –interrupt of drives power supply)
The key switch on the hand control unit may be used only by
knowledgeable and instructed persons, because in TEST mode there is an
increased risk of damage.

ICP 3020 / ICP 4030 iMC-P Operating instruction
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Please keep the replacement key switch under your personal check.
The operator has guarantee sufficient ventilation according accruement of
dust or gas, caused by the operation process of working pieces.
If the sound pressure level near the machine should be higher than 70
dB(A) the operator has to wear an applicative ear protection.
The work at and with the machine is only allowed for authorized,
knowledgeable and instructed persons. Those persons have to be informed
by a special instruction about possibly appearing endangerments
(especially residual risk).
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.
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 maintained only by authorized, trained and
instructed personnel. An instructed person is who was on her teaching duties
and the possible risks for improper conduct and, where necessary trained and
instructed on the necessary safety equipment and protective measures. Such
personnel must have received an instruction about possible dangers. As a staff
can judge who is due to his technical training, knowledge and experience and
knowledge of the relevant provisions of the delegated work and identify possible
dangers. If the staff does not have the necessary knowledge, it must be trained
accordingly.

ICP 3020 / ICP 4030 iMC-P Operating instruction
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4 Delivery status from the factory (quality safety)
To test the machine accuracy of the CNC machine the circular form measuring system
Renishaw QC10 is used.
With this system will be the accuracy of axles all produced CNC machinery / CNC base
machinery checked before delivery.
Circular form measuring system QC10
The assembly of the QC10 is possible at each machine, and takes only a few minutes to
complete. The measuring is controlled via a simple, standard CNC program.
The data are obtained and evaluated in the diagnostic software and the errors with their
size and the corresponding impact on the overall accuracy are shown in graphical / tabular
form.
The form of recognized circles (in all three interpolation planes XY / XZ / YZ) provides
guidance on any existing machine error:
tracking error / position tolerance
straightness error / perpendicularity
measure error / backlash
quadrant transitional / circular form tolerance
The measurements are made depending on the size of the measured axis with a radius of
50mm, 100mm, 150mm and 300mm. It is always the shortest axis considered.
The delivery of any CNC machine made only when all parameters are within the prescribed
limit. The results of the measurements are machine-or order-saved and archived.
Picture: circular form measure with Renishaw QC10

ICP 3020 / ICP 4030 iMC-P Operating instruction
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5 Installation and connection of the CNC machine
5.1 Dimensions and space requirement
The space requirement of the machine is limited to the external measurements and to
sufficient room in front of the machine 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 instructed personnel during a maintenance resp. service
phase!

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5.2 Transport of the CNC machine
Remove the transport lock from the frame feeds. Use only appropriate lifting equipment
(fork lift, trucks, see picture). Lift the machine only from below and do not pull up on the
cover. In case of a later transfer, please make sure that the net and connection cables are
not damaged.
Unplug the power supply cable before each transport.
Take care during transport that the machine is not suspended to heavy
vibrations.
Keep the 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 manufacturer isel Germany AG.
Place the machine on a plane and solid
area. You can compensate the
unevenness of the floor / table with the
adjustable feet. For precise alignment
of the machine you need a spirit level
with an accuracy of at least 0.1 mm/m.
Save the height of the machine feet
with the lock nut.

ICP 3020 / ICP 4030 iMC-P Operating instruction
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5.4 Coordinate system and reference point
The coordinate system of the machine is determined as shown in the figure. However, you
can select (displace) the P0 work piece zero point freely via software.
Ex works, the home position of the machine (machine origin) is defaulted to the back (Y), to
the left (X), and to the top (Z).
Labels on the machine mark the axes.
5.5 Tooling machine
In the collet (4) the standard tooling machine can take 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 terminal block,
loosen the clamping screw and take the tooling machine from the
holder.
For dismantling the machine with the holder, remove the electricity
cable, the two outside screws (3)  (loosen only, do not screw very out)
and remove the machine with holder and T-slot stones downwards.

ICP 3020 / ICP 4030 iMC-P Operating instruction
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Using corresponding holders, you can also attach many other tools, measuring instruments
(laser), or other suitable equipment to the T-slot plate of the Z-axis.
Use the branch box at the Z-axis for the electrical connection.
If you want to mount the tooling machine or other tools again, you must realign the holder
parallel to the XY-plane.
The tooling machine is directly wired and switchable by software. Also other optional digital
outputs can be used to switch peripheral devices (see technical 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 resp. in
the door ensure during operation of the machine (setup or working process) protection
against moving machine parts as well as eventually thrown work piece fragments from the
work area.
You are not allowed to put a CNC marked CNC machine into operation if
the enclosure is not complete, intact or the polycarbonate panes ore
damaged.

ICP 3020 / ICP 4030 iMC-P Operating instruction
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6 Assembly and operation
On delivery:
are all control elements to the security circuit of the machine control
is the main spindle drive (without speed control 100-230VAC 500 –750 W or with
speed control 750W )
are depending on customer requests 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 accordance with EN 60204-1.
Please not the technical data of the machine as well as the connections.

ICP 3020 / ICP 4030 iMC-P Operating instruction
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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

ICP 3020 / ICP 4030 iMC-P Operating instruction
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6.3 Connectors
6.3.1 Connectors on the back side of the machine
number
designation
description
1
serial interface (RS232)
SubD-9-pin plug
Communication between stepper motor control 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 time-lag
3
ground
grounding screw M4

ICP 3020 / ICP 4030 iMC-P Operating instruction
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6.3.2 Control elements on front side of the machine
No
notation
description
1
emergency stop button
Turns off the power supply for the motor power amplifiers and the working spindle in case of any danger.
This means dangers for the users health or machine safety. The integrated security circuit is applicable
category 2 with PL c according to EN 13849-1.
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:
- Main power switch on the controller back side is switched on
- Emergency stop button is pulled out
Be sure that the contacts for external emergency stop switch
on the remote connector (see chapter 6.4.2) are bridged!

ICP 3020 / ICP 4030 iMC-P Operating instruction
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3
operation mode switch
(key switch)
Use this switch to choose between automatic- and test-mode. In automatic-mode (AUTO) you can only
open the cover or safety door of the machine if no axis is in motion and the mounted working spindle
is switched off (means that spindle does not turn).
In the test-mode (TEST) you can only open the cover or safety door of the machine if the mounted
working spindle is switched off (means that spindle does not turn). You can just move the axes at
opened cover or safety door if the spindle is switched off.
When switching from the operation mode AUTO onto the operation mode TEST a running working
spindle will be immediately switched off. The enable signal for the hood / machine door (COVER button
lighted) takes place with a time delay in order to guarantee that the working spindle can run 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 the execution of the user program by pressing the start button.
If you press the stop button in DNC mode an active user program / axis motion will be stopped. To continue
the execution of the user program you have to use the controller software (ProNC, Remote).
6
fault-lamp
The fault lamp indicates an error within the safety circuit.
7
cover-button
Use this button to open the machines cover or safety door. This is possible only if the conditions from point
“4 – operation mode switch“ are complied. An enable for opening of the cover or safety door is signalized by
a white lighted cover button.
8
ACK (ACKnowledge)
This button has no function on the machine ICP 3020 / ICP 4030.