Isel ICP 4030 Assembly Instructions

ICP 4030
ICP 3020
ICP 2015
Platz für Typenschild
Ãi-CNC Compact Equipment
Ãi-CNC Machine
"«iÀ>Ì}Ê>`Ê>Ìi>ViÊÃÌÀÕVÌ
°ÓnäÓÝÝ°äÉÓääΰÎxÉ

Ó
isel Ê«>VÌÊµÕ«iÌÊ*
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

Î
isel- Ê«>VÌÊµÕ«iÌÊÊ*
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.
£° /iÊ*Ê>ÃÊ>ÊV«iÌ]ÊÌÞ«iÊ£
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.
Ó° /iÊ*Ê>ÃÊ>Ê>Vi]ÊÌÞ«iÊÓ
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.
ΰ /iÊ*Ê>ÃÊ>ÊV«>VÌÊiµÕ«iÌ]ÊÌÞ«iÊÎ
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.

{
isel Ê«>VÌÊµÕ«iÌÊ*
You find
- 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
ÌiÌÃ
£ Ìi`i`Ê«ÕÀ«Ãi °°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°° °x
Ó ÌiÃÊÊÃ>viÌÞ °°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°° °È
Î -iÌÊÕ«Ê>`ÊViVÌ} °°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°° °n
{ i>}ÊÉÊ>Ìi>Vi°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°° °£ä
x ÃÃ} °°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°° °£Ó
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
È /ÀÕLiÃÌ} °°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°° °£
Ç /iVV>Ê`>Ì>ÊÉÊ>VViÃÃÀÞ °°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°° °Ó£
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
n ««i`Ý °°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°°° °ÓÈ
Certificate of conformity .......................................................................................................... .26
Service waybill ........................................................................................................................ .27

x
isel- Ê«>VÌÊµÕ«iÌÊÊ*
£ Ìi`i`Ê«ÕÀ«Ãi
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.).
ÞÊvÀÊÌÞ«iÊÓÊ>`ÊÎ
- 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).
ÞÊvÀÊÌÞ«iÊÎ
- 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.

È
isel Ê«>VÌÊµÕ«iÌÊ*
Ó ÌiÃÊÊÃ>viÌÞ
- 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.

Ç
isel- Ê«>VÌÊµÕ«iÌÊÊ*
}}ÊvÊ->viÌÞÊ*>iÃ
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.

n
isel Ê«>VÌÊµÕ«iÌÊ*
Î -iÌÊÕ«Ê>`ÊViVÌ}
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.
ÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊÊiÃÃÊ>`Êë>ViÊÀiµÕÀiiÌ
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.


isel- Ê«>VÌÊµÕ«iÌÊÊ*
ÓÊÝ
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.
LÛiÊ>]Êii«ÊÌiÊÌÀ>}Õ>ÀÊÜÀiVÊ>Ü>ÞÃÊ ÕÌÃ`iÊvÊÌiÊ>ViÊ`ÕÀ}
ÌÀ>ëÀÌ>Ì°
The V>«}ÊÃiÌ is made up by a hand
lever clamping assembly and two stop
bars with mounting hardware for the T-slot
plate.
Ü>ÞÃÊiÃÕÀiÊÌ>ÌÊÌiÊÜÀ«iViÃÊ>ÀiÊ«À«iÀÞÊÃiVÕÀi`°
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.

£ä
isel Ê«>VÌÊµÕ«iÌÊ*
{ i>}ÊÉÊ>Ìi>Vi
Open the hood before switching off the machine using the mains switch. After this, this is no
more possible (only type 2 and 3).
-ÜÌVÊvvÊÌiÊ>ÃÊÃÜÌVÊLivÀiÊ>ÞÊVi>}Ê>`Ê>ÞÊ>Ìi>Vi°ÊÃ]Ê«ÕÊÌi
«ÜiÀÊ«Õ}ÊÊÀ`iÀÊÌÊ«ÀiÛiÌÊ>Ê>`ÛiÀÌiÌÊÃÌ>ÀÌ}°
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.

££
isel- Ê«>VÌÊµÕ«iÌÊÊ*
S
S
S
In order to lubricate the Y-axis, you must
completely push* the T-slot plate to the
front. Next, unscrew (six screws) it from the
Y-axis.
Remove the plastic plug lying under it and
lubricate through the now visible lubricating
nipple.
You reach the shaft guides through the
sealing lips.
Loosen the all around holding-down screws
in order to remove the cover sheet of the Y-
axis.
in all drawings is the characterize accesses
to the greasing points.
To lubricate the X-axis, move the
sledge to the left*. Remove the
plastic plug on the left side of the
machine and lubricate through the
now visible lubricating nipple.
You access the shaft guides again
through the sealing lips.
At the Z-axis, you must first take the tooling machine
from its support. Remove the three plugs and push the
sledge completely down*. You can apply some oil
onto the shaft guides through the two side holes.
The lubricating nipple for the drive is now behind the
front opening.
IÊ9ÕÊV>Ê`ë>ViÊÌiÊÃi`}iÊÕÃ}ÊÌiÊ>`ÊvÊÌi
>ViÊÃÊvv°

£Ó
isel Ê«>VÌÊµÕ«iÌÊ*
/iÊvÕÀÌiÀÊ`iÃVÀ«ÌÃÊvÊV>«ÌiÀÃÊxÊ>`ÊÈÊÞÊ>««ÞÊÌÊ>ViÊÌÞ«iÃÊÓÊ>`Êΰ
x ÃÃ}
x°£ *Ài«>À>ÌÃ
For controlling the CNC machine and/or the FLASH EPROMs, you require one
IBM compatible computer with a free serial interface.
System request - 486 SX, 40 MHz and higher
- 8 MB RAM
- 20 MB of free hard disk capacity
- VGA card
- MS-DOS 5.0 and higher
Connecting cables
The serial port is used as an interface of the machine to the computer using the enclosed
cable (max. three meters in length, you find the pin assignment of the 9-pin Sub D
connector in the Specification section).
Connect the red
connector of this cable to
the PC. This side of the
cable is again marked
with <<PC/AT<<.
Connect the gray coupler
on the reverse side of the
ICP.
Use the multiple socket
strip for connecting
power to the computer
and to the machine.
Connect the power cable
only if the machine is
ready for commissioning.
Mount the >ÝÃÊvÊÀÌ>Ì (optional) onto the T-slot plate in accordance with the assembly
and operating instructions of the axis of rotation in the appendix. Connect the cable to the
axis of rotation and the female Sub D-9 connector in the rear wall of the working space.
How to precisely set up the axis of rotation is also described in the assembly and operating
instructions in the appendix.

£Î
isel- Ê«>VÌÊµÕ«iÌÊÊ*
Installation of the software
In addition to the machine driver (I5DRV), the HPDOWN, REMOTE and ISY-CAM - both only in
case of type 3 - software packages are provided for setting-up of the machine and processing
the parts.
At first, install the driver for the machine onto your computer (DOS-modus):
£° Insert the driver floppy disk (i5drv starting with type 2.1) into your disk drive for the ICP.
Ó° Access the disk drive by entering “A: (return) and/or B:” .
ΰ Start the installation program with “install” and/or “install -e” (in English).
The program installs the driver.
{° Add the following line to >ÕÌiÝiV°L>Ì\
-iÌÊÃiÚxr\MxMV{° (“cd ..” “edit autoexec.bat” )
x° Start the driver with “cdi5” and “i5drv” (to start, the machine must be
connected and turned on).
Please refer to the notes in the corresponding manuals and/or in the Readme files on the
floppy disks for the installation of the supplied device operating programs. You find all
descriptions for using the software in the enclosed manuals.
Leadscrew pitch
By default, the I5DRV machine driver is set to a leadscrew pitch of 10 mm. You must change
a setting in the I5DRV machine driver so that the traversing speeds and the measure of the
axes agree with inputs during the operation if your machine has a pitch of 4 mm.
The machine driver must be installed. The machine must be connected and turned on.
ÊÊ£° Go to the I5 directory: “cd i5” .
ÊÊÓ° Select the machine driver: “i5drv” .
ÊÊΰ Run the adjusting program: “i5ein” (press 2x). On the screen, a window appears in
which you can perform the necessary settings.
ÊÊ{° Open the *>À>iÌiÀÃÉ>}iÊmenu.

£{
isel Ê«>VÌÊµÕ«iÌÊ*
80C196KC
1
2
3
ÊÊx° In the small window, set the lead screw pitch to 4 mm for every axis.
ÊÊÈ° Change the traversing ëii`ÃÊto a maximum of 20 mm/s (only with a 4 mm pitch) to
avoid resonances.
ÊÊÇ° At the end of changes, move down to ` using the scroll bar .
ÊÊn° Save the changes using: *>À>iÌiÀÃÉ->ÛiÊ °
You must initialize the driver again (*>À>iÌiÀÉÌÊ`ÀÛiÀÃÊitem )Êif you want to
immediately carry out a test (e.g., move axes)°Otherwise, this is automatically
performed by running the program again.
ÊÊ° Exit the setting program using: Quit .
£ä° Deactivate the machine driver: “i5drv” .
The new settings become valid on the next call of the driver.
Setting of the transfer rate (baud rate) and/or of the delay period.
With the H1jumper field, you can set the transfer rate (9 600 or 19 200 bauds) and/or the
delay period of the hood switch (1 or 5 seconds).
- The baud rate is the transfer rate of the serial interface of the computer communicating
with the controller (see the manual for further information).
- Delay is the time passing by between the switching-off of the tooling machine (or the end
of tooling) and the releasing of the COVER button for opening the hood. Delay is used to
wait for the running out of the tooling machine to avoid dangers. Especially with
educational and training applications, 5 seconds of delay are reasonable and should also
be set.
*ÕÊÌiÊ«ÜiÀÊ«Õ}ÊLivÀiÊÞÕÊ«>ViÊÕ«iÀÃÊÀÊÀiÛiÊÌi°
The jumper field is on the printed circuit board (in the figure on page 19, position 12).
- Ex works, all jumpers are open, i.e. the baud rate is set to
19 200 bauds and the delay to approx. 1 second.
- A jumper between pin 1 and pin 2 sets a baud rate of
9 600 bauds.
- A jumper pin 1 and 3 between extends the delay period to
approx. 5 seconds.
The new setting is taken over with the powering-up of the machine.
All other jumpers on the printed circuit board must not be modified!
jumper field H1
processor

£x
isel- Ê«>VÌÊµÕ«iÌÊÊ*
*
0
Coordinate system
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.
The order of the axial directions is freely selectable. Please, read the manual of the I5DRV
driver for this purpose.
Tooling machine (only in the case of type 3)
In the collet ➃, the standard tooling machine can take tools with a maximum shaft diameter
of 6.35 mm (standatd 3 mm, other diameters see Accessory). Use two SW 22 open end
wrenches for changing the collet.
The current for the tooling machine is only enabled by
the software. You can manually adjust the rotation
speed of the machine using the ➀wheel.
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
➂(loosen only, do not screw very out) and remove
the machine with holder and T-slot stones
downwards.
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.

£È
isel Ê«>VÌÊµÕ«iÌÊ*
16 2345
x°Ó «ÀÌ>ÌÊ«iÀ>Ì}ÊvÀ>Ì
Push-buttons and switches
The black >ÃÊÃÜÌV is located on the rear side of the machine directly beside the mains
connection.
Using the switches and/or push-buttons on the front side, you can switch the machine on and
off and start and stop the processing in a purposeful manner.
➀iÀ}iVÞvv
Abort of all functions; the error status remains
testable using the software; after a delay,
the hood can be opened using the ➅push-
button. Releasing Emergency-Off by turning to
the right.
➁*"7,
You can only turn on the power stage if Emergency-Off is released.
➂iÞÃÜÌV
Using the key, you can switch between test and automatic operation.
AUTO = processing mode
In the automatic mode, the machine either works stand-alone based on the
program that is stored in the FLASH EPROM (CNC mode) or via the connected
supervisory computer (DNC mode). You can interrupt tooling using STOP and
continue to work using START.
TEST = test mode
In this operating mode, you can open the hood at any time if the tooling machine
is switched off. You can continue to process the programs. However, the tooling
machine is switched off if the hood is opened and can not be switched on again.
The sledge remains freely moveable also with manual traversing (teaching).
/>iÊV>ÀiÊvÊÌiÊLiÊÃi`}i\ÊÊ>}iÀÊvÊLÀÕÃ}t
*>ÞÊ>ÌÌiÌÊÌÊÌiÊÛ}Ê`i«Ì\ÊÊÃÊ`>}iÀÊÜÌÊÌiÊÜÀÊ«iVit
➃-/,/
- If a program is stored on the FLASH EPROM then the program is started by pressing
this button independently of whether a computer is connected or not.
- After a hold using the button ➄, the machine restarts the stopped movement
exactly at the location where it was interrupted provided that tooling has not being
terminated via the man-machine interface.

£Ç
isel- Ê«>VÌÊµÕ«iÌÊÊ*
➄-/"*
Execution of the current program is immediately stopped and remains at the (program)
location. The tooling machine is switched off. In the DNC mode, you can issue further
commands via software. This is not possible in the CNC mode.
After a time delay of 1 or 5 seconds, the COVER button lights up and you can open the
hood. With a closed hood, you can continue the program by pressing the START
button.
➅"6,
Only if the button is lit, you can open the hood by pressing this button (first, press the
button, then pull simultaneously at the grip!). In the unfavorable case if you set only a
delay period of one second, the spindle can continue to rotate for a few seconds.
ÊÌÊÀi>VÊÌÊÌiÊÃÌÊÀiÛÛ}ÊÌ°
x°Î /iÊ-Ê*," (use only for free programming)
You can permanently store a processing program for the machine on the FLASH EPROM.
You can erase it again and store a new program. The machine can thus be started
independently of the controller and process a work piece (CNC mode).
This operating feature is especially suitable for small series productions.
You must erase the FLASH EPROM before you can write to it again.
Erasing the FLASH EPROM:
1. Turn on the mains switch (Emergency-Off released, POWER not pressed)
2. Activate the TEST mode
3. Keep the STOP button pressed and press the POWER button once shortly
Please, read the corresponding manual for the coding of programs and saving these onto
FLASH EPROM (programmer’s guide of the IMC4 2.xx).

£n
isel Ê«>VÌÊµÕ«iÌÊ*
x°{ ÀÃÌÊVÃÃ}
During the first commissioning, you should carry out the following steps:
- For the first opening of the hood, connect the power cable and turn on the mains switch.
The COVER button ➅should light up now; you can open the hood if this button is lit.
- Emergency-Off must be released for all following functions.
- Close the hood and turn on the power stage using the POWER push-button ➁;
the push-button must light up.
- You can execute the software at any time. However, an error message is displayed if the
machine is not operational (power stage turned on).
- You can start a program stored on FLASH-EPROM by pressing the START button.
Of course, the machine must first be set up correspondingly.
- The hood is locked while tooling. You can only open the hood after the machine stands
still, the tooling machine is off, and the software enables the opening of the hood
(the COVER button lights up).
- You must press the COVER button for opening the hood. The hood is automatically locked
after closing. To start the machine, you must press the START button again.
Please, refer to the corresponding software manual for all further information on working
with the software.
Keyswitch
For debugging the program, you can nevertheless open the hood during the operation if
you turn the keyswitch to TEST (test operation). In this case, the tooling machine must be
switched off but the work program is continued.
Take care to retract the tool from the work piece!
/ÃÊiÞÊ>ÞÊÞÊLiÊÕÃi`ÊLÞÊiÝ«iÀÌÊ>`Ê>ÕÌÀâi`Ê«iÀÃiÊÃViÊÊ«ÀÌiVÌ
>}>ÃÌÊÛ}Ê>ViÊ«>ÀÌÃÊÃÊ>Û>>LiÊ>ÞÀiÊ>vÌiÀÊ«i}ÊÌiÊ`°
Tooling machine (only in the case of type 3)
The tooling machine is directly wired and switchable using the software.
The same applies to the three other switchable outputs (optional) that you can use to switch
optional devices (refer to the technical data).
The tooling machine can only be turned on if the POWER button is lit, the hood is locked
close, the rotary switch at the machine is set to ON, and the software controls the machine.

£
isel- Ê«>VÌÊµÕ«iÌÊÊ*
1
2
È /ÀÕLiÃÌ}
ÊÊÊÊÊÊÊÊÊÊ>ÕÌ ÊÊ>ÕÃi ,ii`Þ
Equipment can not be turned on No mains power is available check the mains circuit,
power plug, multiple socket outlet
Mains switch is not turned on turn on the mains switch
Fuse is defective *ÕÊÌiÊ«ÜiÀÊ«Õ}
replace the fuse (see below)
POWER button does not function Hood not closed close the hood
Emergency-Off not released release Emergency-Off
Fuse is defective *ÕÊÌiÊ«ÜiÀÊ«Õ}
replace the fuse (see below)
Software does not work correctly Equipment not turned on turn on the equipment (mains switch)
Power stage not turned on activate power stage (POWER button)
Driver not loaded install the driver
Connection is not correct check the cable connectors
Tooling machine (spindle) Not released by the software reset the equipment and perform
does not function a reference movement
Rotary switch at the turn on the tooling machine
tooling machine is off
Fuse is defective *ÕÊÌiÊ«ÜiÀÊ«Õ}
replace the fuse (see below)
Scaling of the axes Leadscrew pitch does not corres- Change the leadscrew pitch in the
is not correct pond to the setting in the software driver program to 4 or 10 mm
First movements do not correspond EPROM contents a program Delete the EPROM (s. page 16)
to the programm
ÕÃiÊÀi«>ViiÌ
*ÕÊÌiÊ«ÜiÀÊ«Õ}ÊLivÀiÊV>}}Ê>ÞÊvÕÃit
The main fuses of the machine ➀are amenable from the outside. They are located directly
beside the power plug.
Remove the large rear-panel for
changing the other fuses. You find the
main fuse for the motor voltage ➁in
front of the transformer in the black
plastic holder (➀+ ➁: 6.3 A each ).
The remaining fuses are located on
the controller printed circuit board.

Óä
isel Ê«>VÌÊµÕ«iÌÊ*
Please refer to the following drawing for the positions of fuses (➁, ➃, ➅, ➆, ➈) and LED’s
(➀, ➂, ➄).
ÌÀiÀÊ«ÀÌi`ÊVÀVÕÌÊL>À`ÊLi`ÊÌiÊÀi>À«>i
➀Controller LED Processor supply voltage 10 V/5 V
➁Input fuse 1,25 Amp, slow ones
➂Controller LED 24 V I/O voltage
➃Input fuse 1,25 Amp, slow-blow
➄Controller LED 24 V safety circuit voltage
➅Input fuse 1,25 Amp, slow-blow
➆Supplementary output fuse 230 V, 1,25 Amp, slow-blow HBD
➇Supplementary output connector 230 V
➈Tooling machine fuse 230 V, 5 Amp, slow-blow HBD
➉suppl. outp. 9-pin Sub-D f. con. 15 mA max.
suppl. inp. 9-pin Sub-D fem. con.
H1 jumper field
For special cases (if a switch is defective or in case of power failure etc.), you can manually
open the hood interlock using the triangular wrench.
£° Switch off the machine.
Ó° Remove the four screws of the sheet metal lid of the chassis, then remove the lid.
ΰ Insert the triangular wrench into the interlock from the back and turn it around half a turn
to the left without applying excessive force.
9ÕÊ>ÞÊÌÊ«iÀ>ÌiÊÌiÊ>ViÊÊÌÃÊÃÌ>Ìi°
The tooling machine remains de-energized.