Isel ICP 4030 Assembly Instructions

ICP 4030
ICP 3020
ICP 2015
Platz für Typenschild
Ãi-CNC Compact Equipment
Ãi-CNC Machine
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On this Manual
Various symbols are used in this Manual to quickly provide you with brief information.
Danger Caution Note Example Additional
Information
© isel Germany AG 2009
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.
Ãi 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.
isel Germany 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: isel Germany AG
Bürgermeister-Ebert-Str. 40
D-36124 Eichenzell
Fax: [phone]
E-Mail: [email protected]
http://www.isel.com

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This manual includes the instructions for all machines of the ICP type.
The ICP is provided in three different system configurations. However, this listing also specifies
which part of the instructions is relevant for you. This applies also to the chapters.
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The case is supplied including the driving axes, without electronics, without software,
without tooling machine. With this system configuration, you can employ and connect
your own controller electronics. A tooling machine is also freely selectable.
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In addition to type 1, this system configuration includes an Ãil controller for the linear
axes. It contains a safety circuit and some optional inputs/outputs (24 V and/or 230 V).
For this purpose, you receive the Ãil HPDOWN software and the I5DRV machine driver.
The tooling machine is freely selectable.
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The complete installation (mechanics, electronics, tooling machine and software
(ISY-CAM + REMOTE, I5DRV)) is immediately ready after commissioning.
At every expansion level, the ICP is a compact machine that offers an abundance of
possibilities for processing work pieces.
As a prerequisite for your work with the ICP and depending on the implementation, you
require basic knowledge in CNC engineering and PC application, a computer, a mains
socket, and some creativity.
*i>Ãi]ÊVÃ`iÀÊÌiÃiÊÃÀÌÊÃÌÀÕVÌÃÊÌ
• properly commission the equipment,
• fast, safely, and effectively work,
• keep away dangers of persons,
• and thus exploit the full potential.
To get acquainted to work with this machine, we recommend that you carry out the
processing example which is appended to these instructions (for the ICP with the HPDOWN,
REMOTE, and/or ISY software).
We wish you a lot of success. Enjoy your future working with the ICP.

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- iiÀ>ÞÊÛ>`ÊÌià in chapters 1, 2, 7 and 8
- Description of theÊiV>VÃ in chapters 3, 4 and 7
- Description of theÊiiVÌÀVÃ in chapters 5, 6 and 7
- Description of theÊÃvÌÜ>Ài in the processing example (appendix) and in separate
manuals
- Description of theÊ>VViÃÃÀÞ in the appendix
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5.1 Preparations ............................................................................................................................ .12
5.2 Important operating information ............................................................................................. .16
5.3 The FLASH EPROM (use only for free programming) ............................................................ .17
5.4 First commissioning ................................................................................................................ .18
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7.1 Accessory ................................................................................................................................ .21
7.2 Pin assignment ........................................................................................................................ .22
7.2.1 For the ICP with electronik ...................................................................................................... .22
7.2.2 For ICP without electronic ...................................................................................................... .24
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Certificate of conformity .......................................................................................................... .26
Service waybill ........................................................................................................................ .27

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The ICP is a machine tool with three linear axes that can electronically be controlled.
A further (rotary) axis is available in addition.
- The machine is planned for training and the small assembly line production.
- It is designed for the application in dry rooms, business rooms, living and training areas
and in labs and small firms (maximal ambient temperature 40° C).
- The machine is suitable for milling, boring, cutting, engraving, proportioning, metering,
positioning, and many similar applications.
- You can install the most different suitable tooling tools or mount instruments, appropriate
for the above mentioned applications.
- Suitable tooling materials are light metal, plastics, wood, glass, printed circuit materials.
For safety reasons, graphite is not permissible (danger of explosion) as material.
Also not admissible are materials that produce health-endangering gases during
processing.
- The machine is prepared for a suction apparatus. With preference, this suctioning is
suitable for dry dust kinds (wood, printed circuit boards, etc.).
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- The complete controller and power electronics of four axes are contained in the controller
of this machine. The IMC4 controller (interpolation operation) is installed in the ICP.
The machine can also be operated in the CNC mode using the integrated FLASH EPROM.
- Using any computer, you can actuate the machine with the IMC4 controller via the serial
interface. In addition, you may execute an already internally stored processing program
(in flash EPROM) without computers.
- Optionally, two 24 V outputs, two 24 V inputs, and a 230 V output are available for
connecting further components (e.g. resistive loads).
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- With the ISY CAD/CAM software, you can directly pass on the previously generated
CNC data to the machine and initiate the processing of the work piece via a corresponding
controller program.

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- The machine must not be operated in a blast capable atmosphere.
- The machine is completely encapsulated. The casing protects you against moving tools,
decreases the operating noise level, and restrains the chips.
- While tooling, the hood is locked and can not be opened.
You may neither remove nor modify this protection measure (only type 2 and 3).
- Hardware and software are included in the safety circuit i.e. the machine functions only
with the appropriate and intact controller heart on the printed circuit board
(only type 2 and 3).
- For emergency situations, you find an Emergency-Off switch on the front-panel of the
machine.
It interrupts the power supply to the power module and tooling machine.
However, the software - machine communication remains possible for fault tracing
(only type 2 and 3).
- Only experts and trained persons may handle the keyswitch since a higher risk exists in
test mode (only type 2 and 3).
Please, keep the alternative key under lock and key.
- All 230 V loads are only single-pole switched. You must assume that an interrupted load is
not necessarily voltage-free (only type 2 and 3).
- Ensure sufficient ventilation at dust or gas development that is caused by processing the
materials.
- Use only suitable devices (laser class 2) if you want to apply a laser for measuring
applications. Consider the corresponding technical regulations.
- For cooling, no flowing water may be used but only a sprinkle/chilling appliance with
which a spray causes the cooling effect (see accessories).
No drops may form themselves and flow under the clamping plate.
- Do not use spirit as coolant (danger of explosion!).
- Clean the machine regularly and remove chips and dust deposits.

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Investigations, accomplished by the Association of German Machine Tool Factories (VDW) in
connection with the responsible employer's liability insurance association have pointed out
new aspects about the aging of polycarbonate as material for safety panes at machine tools.
Although polycarbonate worked very good for this purpose, these panes sometimes
substantially lose their ability to hold back flying around parts, especially under the influence
of cooling lubricants. At longer term, polycarbonate panes that are double-sided protected
against the effects of splinters, cooling lubricants, detergents, steams, etc. have hereby
shown the highest resistance.
In order to set you in the position to carry out your care business, we would like to point out
that safety panes made of polycarbonate are therefore to be examined regularly for their
retaining abilities and to be changed if necessary. Additionally, such safety panes are to be
classified as wearing parts in future. Beyond that, when you sale it, you are also obligated to
inform the possible buyer of such a machine accordingly about that.
Even with consideration of these new realizations polycarbonate will be further used as
material for safety panes in mechanical engineering due to its extremely high retaining ability.
Spare panes ready to be installed can therefore be ordered from us at any time. In order to
increase the necessary exchange intervals, we can also offer a retrofit kit for an additional
protection on the operator side if desired.

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The machine is provided completely mounted on a palette.
Contained in ÃV«iÊvÊ`iÛiÀÞ of the ICP are:
• machine case with three linear axes included
- complete controller electronics (only type 2 and 3)
- drilling and milling machine with 3 mm split chuck - as a standard (only type 3)
• key for split chuck, SW 22 (only type 3)
• clamping set (hand lever, stop bars, 5 mm socket spanner)
• triangular wrench for unlocking the hood switch
• AC power cable, PC - machine data cable (only type2 and 3)
• 4-fold socket outlet with illuminated mains switch (only type 2 and 3)
• Driver software for DOS including setup program, 1 floppy disk, 1 manual (type 2 and 3)
• PRO-PAL program, 1 floppy disk, + processing example (only type 2)
• REMOTE program, 1 floppy disk, + processing example (only type 3)
• ISY-CAM CAD/CAM software (only type 3)
• and these service and maintenance instructions
The ë>ViÊÀiµÕÀiiÌ 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.
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Remove the sheet steels of the feet of the machine with which it is secured on the palette.
Then, set up the machine horizontally onto a flat, fixed face.
You can compensate for small unevenness of the base area at the feet.

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During transportation, please pay attention to the supply and connection cables (remove if
needed) so that they are not damaged. Use only suitable lifting devices.
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The V>«}ÊÃiÌ is made up by a hand
lever clamping assembly and two stop
bars with mounting hardware for the T-slot
plate.
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iVÌÃ to the controller of the machine (type model 1):
➀Z-axis (Amphenol connector)
➁X-axis (Amphenol connector)
➂Y-axis (Amphenol connector)
➃A-axis (axis of rotation )(Amphenol connector) The pin allocation of
➄START and STOP push-button (9-pin connector) the connectors ➀ - ➆
➅hood switch (9-pin Sub D connector) is located in the
➆POWER / emergency push-button (15-pin connector) technical data
➇grounding point
➈tooling machine
For the >VViÃÃÀiÃ] different parts are already pre-installed or prepared for mounting.
For this purpose, also read the information in the appendix.
You can connect the cable of a tooling machine to the coupler
terminal block in the branch box at the side of the Z-axis.

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Open the hood before switching off the machine using the mains switch. After this, this is no
more possible (only type 2 and 3).
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Clean the machine regularly with a broom or vacuum cleaner of all chips (no compressed
air). That protects the mechanics against early wear.
- With frequent machining operations and very fine chips (dusts), you should regularly
remove the cover plate of the Y-axis below the T-slot plate and remove possibly penetrated
chips and/or dusts.
- The sealing lips include a Teflon component and require no special maintenance.
- Clean the perspex windows with a non-abrasive fluid cleaner.
- The shaft guides and drive shafts are provided with a long-term lubrication ex works.
Depending on the load, you should grease the shaft guides and drive shafts approx. all
500-1000 operating hours. Use usual rolling bearing grease for that purpose.
Ex works, the shaft guides and shafts are lubricated using GP00/000F-20 sodium soap
grease according to DIN 51 502.
Please, you lubricate all 100-200 operating hours if you use oil.
At first, make a reference movement for lubricating the driving axis. Then, open the hood
and only now switch off the machine.