isel-CNC Machine - Bedienungsanleitungen / Manuals isel

isel-CNC Machine 

Operating and Maintenance Instruction 

B.2801xxV/2001.22/E 

Platz für Typenschild

isel-CNC Machine CPV 

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 1998 

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 GmbH & Co.KG 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-Str. 40 

D-36124 Eichenzell 

Fax: +49-6659-981-776 

E-Mail: automation@isel.com 

http://www.isel.com 

2


The CPV is a compact machine with servomotors, which provides an abundance of 

possibilities for machining workpieces. 

The advantages in comparison with stepper motor control systems are: 

- higher traversing speeds 

- lower noise, no resonance effects 

- continuous-path control 

- exact positioning using position control with position encoder 

The machine is offered in different variants: 

- The standard variant incorporates the complete electronics including the isy-CAM and 

REMOTE software, as well as a main spindle drive. 

- The second variant incorporates the machine without electronics. That means that you can 

use your own control system. 

For the exact extent of delivery and the machine specification / accessories that come with 

the machine, please refer to your note of delivery. 

As a prerequisite for your work with the CPV, you will need basic knowledge in CNC 

engineering and PC application, a computer, a mains socket, and some creativity. 

Please follow this brief instruction to be able to 

• properly install the equipment, 

• work in a safe, quick and effective manner, 

• keep away hazards from persons, 

• thus exploiting the full potential. 

We wish much success for your future work with the CPV. 

3


Contents 

1 Intended Purpose ............................................................................................................. .5 

2 Safety Notes ...................................................................................................................... .6 

3 Set-Up and Connection .................................................................................................... .8 

4 Start-Up .............................................................................................................................11 

4.1 Preliminary Remarks ............................................................................................................. .11 

4.1.1 Coordinate System ............................................................................................................... .11 

4.1.2 System Requirements ........................................................................................................... .11 

4.1.3 Push-Buttons and Switches ................................................................................................... .12 

4.2 Installing the Driver Software ................................................................................................. .13 

4.3 Starting the Software ............................................................................................................. .13 

4.4 Opening the Cover ................................................................................................................ .14 

5 Cleaning / Maintenance ....................................................................................................15 

6 Troubleshooting ...............................................................................................................17 

7 Technical Specifications / Accessories ............................................................................19 

7.1 Mechanics ............................................................................................................................. .19 

7.2 Electrical Components .......................................................................................................... .19 

7.3 Starting Up the UPMV 4/12 ................................................................................................... .28 

7.3.1 Base Address ........................................................................................................................ .28 

7.3.2 Interrupt Source of the Servomotor Control Card ................................................................. .28 

7.3.3 Signal I/O .............................................................................................................................. .29 

7.4 Evaluation of Limit and Reference Switches ......................................................................... .33 

7.4.1 Limit Switches ....................................................................................................................... .33 

7.4.2 Reference Switches ............................................................................................................... .33 

7.4.3 Enable ................................................................................................................................... .34 

7.4.4 Safety Shutdown ................................................................................................................... .34 

7.5 Connectors ........................................................................................................................... .35 

7.6 Charts and Tables .................................................................................................................. .37 

7.6.1 Block Diagram of Safety Circuit ............................................................................................ .37 

8 Accessories ......................................................................................................................38 

9 Appendix ...........................................................................................................................39 

Certificate of Conformity ...................................................................................................... .39 

10 Service waybill ................................................................................................................ .40 

4


1 Intended Purpose 

The CPV is a machine tool with three electronically controlled linear axes. 

Another (rotary) axis is offered as an option. 

- The machine is designed for training and small-series production. 

- It is designed for use in dry rooms, business rooms, living and training areas, as well as in 

laboratories and small firms (max. ambient temperature 40° C). 

- The machine is suitable for milling, boring, cutting, engraving, proportioning, measuring, 

positioning, and many similar applications. 

- You can mount a great variety of machining tools or measuring instruments according to 

the above mentioned applications. 

- Suitable materials are light metal, plastics, wood, glass and printed circuit materials. 

For safety reasons, graphite may not be used (explosion hazard). 

Any materials that produce hazardous gases when being processed may also not be 

used. 

- The machine is prepared for a suction apparatus. This suction apparatus is preferably 

intended for dry dust kinds (wood, printed circuit boards etc.). 

- The complete control and power electronics of three axes is housed in the machine. The 

control system is installed in the standard machine. Only the UPMV 4/12 and the multi I/O 

cards are housed in the control computer. 

- A fourth axis can easily be integrated to upgrade the control system. 

- You can control the machine from almost any IBM compatible computer. The only 

prerequisite is that it must have at least three free ISA slots (one for the servomotor power 

card UPMV 4/12 and two for the two multi I/O cards). 

- Eight 24 V outputs and sixteen 24 V inputs are available as an option to connect further 

components. 

- With the isy-CAD/CAM software, you can directly pass on the previously generated 

CNC data to the machine, thus initiating the workpiece to be machined using an 

appropriate control program (REMOTE). 

5


2 Safety Notes 

- Do not operate the machine in potentially explosive atmospheres. 

- The machine is completely encapsulated. The casing protects you against moving tools, 

decreases the operating noise level and restrains the chips. 

- On machining, the cover is locked and cannot be opened. 

You may neither remove nor modify this protection measure. 

- For emergency situations, you find an Emergency Stop switch on the front-panel of the 

machine. 

It interrupts the power supply to the power outputs and to the converter of the main 

spindle drive. The converter therefore no longer provides a brake voltage, and the spindle 

motor slowly runs down. 

- The system should not often be restarted/shut down. Wait at least 60 seconds before you 

turn on the system again. 

- Only experts and trained persons may handle the key-operated switch because of 

increased hazards in test mode. 

Please, keep the spare key under lock and key. 

- Provide sufficient ventilation at dust or gas development caused by the machining of the 

materials. 

- If you want to use a laser for measuring applications, use only suitable devices (laser class 

2) and observe the relevant technical regulations and safety instructions. 

- For cooling, no flowing water may be used but only a sprinkling/chilling appliance with 

which a spray causes the cooling effect (see Accessories). 

Make sure that no drops form and flow under the clamping plate. 

- Do not use spirit as a coolant (explosion hazard). 

- Clean the machine at regular intervals and remove chips and dust deposits. Do not use 

aggressive cleaning agents or solvents that may damage the paint or the plastic washers. 

6


Aging of Safety Panes 

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. 

7


3 Set-Up and Connection 

The machine comes completely mounted on a palette. 

The extent of delivery of the standard CPV contains: 

• Machine housing with three linear axes 

- complete control electronics for three axes 

- main spindle drive (500 W) 

• Mounting set (hand lever, stop bars, 5 mm socket spanner) 

• Triangular wrench for unlocking the cover switch 

• Mains supply cable 

• Driver software for DOS including set-up program “iseldrv”, 1 diskette, 1 manual 

• Software either: 

REMOTE program, 1 diskette + machining example 

CAD/CAM software isy-CAM, 1 CD, 1 manual 

or: 

PRO-PAL program, 1 floppy disk, 1 manual 

• and these Operating and Maintenance Instructions 

The servo motor control card UPMV 4/12s, both Multi I/O cards and the connection cables 

are included in the extent of delivery of the control computer, which you have ordered at the 

same time. 

The space requirements of the machine is limited to the external dimensions and to sufficient 

space in front of the machine to be able to operate and set up the machine. 

Leave approx. 10 cm at the rear side for the plugs and connectors. The cover of the housing 

opens upwards so that the required total height is approx. 1.2 meters. 

ca. 1200 mm 

CPV 4030 

710 mm 

ca. 1320 mm 

Dimensions and space requirements 

Remove the sheet steels from the feet of the machine, with which it is secured on the palette. 

Then, set the machine horizontally on an even, solid surface. 

Use the adjustable rubber feet of the machine to adjust uneven patches of the floor. 

8


During transportation, please pay attention to the supply and connection cables (remove 

them if necessary) so that they are not damaged. Use only suitable lifting devices. 

In particular, when transporting the machine always keep the triangular wrench outside 

the machine. 

The mounting set consists of a 

hand lever clamping assembly and 

two stop bars with mounting 

hardware for the T-slot plate. 

2 x 

Always ensure that the 

workpieces are properly secured. 

For the accessories, different parts are already pre-installed or prepared for mounting. 

Refer also to the information provided in the Appendix. 

Mount the rotary axis (option) on the T-slot plate as prescribed in the Rotary Axis Mounting 

and Operating Instructions. Connect the cable to the rotary axis and to the connector in the 

rear panel of the work space. 

For the selection of the rotary axis, refer to the UPMV 4/12 Operating Instructions. 

The main spindle motor is directly wired and 

software-controlled. Various tools with a shaft 

diameter of max. 6.35 mm (other diameters see 

Accessories) can be mounted in the collet chuck of 

the main spindle motor. To change the collet chuck, 

use the provided tools (SW 15 open end wrench and 

a hook spanner). 

Appropriate holders are provided to attach also 

other tools, measuring instruments (laser) or other 

suitable facilities on the T-slot plate of the Z axis. 

Make sure that these tools are exactly aligned 

parallel to the XY plane. 

9


Connecting Lines 

To link the machine with your computer, please use the provided cables (for servomotor 

control card UPMV 4, multi I/O cards and/or motor cables, diverse control cables). For the 

pin assignment of the Sub-D connectors of the CPV without electronics, refer to the Technical 

Specifications in Section 7.5. 

Connection panel of the CPV with integrated electronics 

➀ Connection of confirmation key (9-pin Sub D connector) 

➁ UPMV 4/12 (50-pin ribbon connector) 

➂ Multi I/O for safety circuit SK (37-pin Sub D connector) 

➃ Multi I/O for user I/O (37-pin Sub D connector) 

➄ Earthing point 

➅ Main switch 

➆ Mains connection 

➇ Fuse (10 A, slow-blow) 

Connection panel of the CPV without electronics 

➀ Z axis 

(Amphenol connector, C16-3)) 

➁ X axis 

(Amphenol connector, C16-3) 

➂ Y axis 


➃ A axis (rotary axis) 


➄ START and STOP keys 

(9-pin Sub D connector) 

➅ Cover switch 

(9-pin Sub D connector) 

➆ POWER / emergency stop button (15-pin Sub D connector) 

➇ Earthing point 

➈ Input of machine tool 

10


4 Start-Up 

4.1 Preliminary Remarks 

4.1.1 Coordinate System 

- The coordinate system of the 

machine is defined as shown in 

the illustration whereby you 

can freely select (move) the 

workpiece zero point P0 via 

software. 

P 0 

- Labels on the machine mark the 

axes. 

- The arrangement of the axis 

positions is free; refer to the ISELDRV Driver Manual. 

Reference point and home position 

By default, the reference point of the machine (machine 

zero point) and the home position are preset to the rear 

corner (Y), left (X) and top (Z). 

The reference point is set by hardware limit switches; the 

home position of the control system is transferred to the 

control system via an electromagnetic switching contact. 

The solenoid as the pulse generator is mounted to the 

housing, and the reading contact on the Z axis senses 

the home position if it receives the pulse from the solenoid. 

4.1.2 System Requirements 

To control the CNC machine, you will need an IBM compatible computer with free slots for 

the servo motor control card UPMV 4/12 and two multi I/O cards. 

System requirements 

- 486 SX, 40 MHz or higher 

- 8 MB RAM 

- 20 MB of free hard disk capacity 

- VGA card 

- MS-DOS 5.0 or higher 

- three free ISA slots 

If you use an isel-controller, it is fit to the machine and ready for start-up. 

11


4.1.3 Push-Buttons and Switches 

The black main switch 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 on/off the 

machine and start or stop the machining process. 

➀ Emergency Stop 

Use this button to interrupt the power supply to the 

motor power output stages and to the spindle 

motor. 

The cover can be opened using the ➅ push-button. 

The Emergency Stop button is unlocked by turning to 

the right. 

6 5 4 3 2 

1 

➁ POWER 

Use this key to turn on the power output stages 

You can only turn on the power stages if the Emergency Stop button is unlocked and the 

cover is closed. 

➂ Key-operated switch 

Use this key to switch between test and automatic operation. 

AUTO = machining mode 

Use STOP to interrupt machining and START to continue. 

TEST = test mode 

In this operating mode, you can open the cover at any time. As long as you hold 

down the START key, all machine functions remain stored. 

Releasing the ACKNOW key with the cover opened will result in Emergency Stop 

and shutdown of the power supply. 

Pay attention to the moving carriage: Hazard of personal injury! 

➃ START 

Use this button to start machining or restart the movement after stop ➄ exactly from the 

position at which the movement has been interrupted if the machining has not been 

completed from the user interface. 

Can be used in test mode to traverse the carriages with the cover open. 

➄ STOP 

Use this key to stop the current program immediately and to hold the program at the 

break point. Use the START key to continue the program with the cover closed. 

➅ COVER 

Use this key to unlock the cover switch. 

Only if the COVER key lights, you can open the cover by pressing this key (first, press 

the key, then simultaneously pull the grip!). 

Do not reach into the tool that may run down. 

12


4.2 Installing the Driver Software 

Install the software according to the UPMV 4/12 Operating Instructions (pages I - VI). 

install.bat 

The directory with the files is already installed on every isel control computer on delivery. 

Among other files, the following files are on the installation diskettes: 

- servo.ini contains the set operating parameters and INSTALL files 

required for the UPMV 4/12 card 

- propal.ini setting values for PRO-PAL (preset) (optional) 

- remote.ini setting values for REMOTE (optional) 

- drv.bat required for starting the iseldrv.exe driver 

- cover.exe required to open the cover without having installed the driver 

4.3 Starting the Software 

Make sure that the machine is correctly linked with the other components (control 

computer, plug-in cards) (as per Chapter 3). 

If the control computer is contained in the extent of delivery: 

1. Turn on the control computer and the machine. 

2. In the control computer, go to the subdirectory “servo”. 

cd servo 

3. Call the batch file “drv.bat” to start the software. 

drv 

4. Start the machining program. 

You can chose from the following programs (depending on your order): 

- REMOTE ® re.bat 

- PRO-PAL (portal equipment) ® ppp.bat 

- PRO-DIN (portal equipment) ® pdp.bat 

You must install the isy-CAD/CAM software by yourself. 

No batch file is prepared. 

If you intend to use your own control computer: 

When have installed the UPMV 4/12 and the two multi-I/O cards, first install the provided 

driver software. (Please proceed as per description of the UPMV 4/12 servomotor control 

card, p. I - VI, see also Section 7.3) 

Carry out all further steps as described above (Items 2 - 4). 

13


4.4 Opening the Cover 

During commissioning, carry out the following steps: 

- To open the cover, connect the mains cable and turn on the mains switch (on the rear side). 

Make sure that the control computer is ready for operation. 

Either start the operating software or the cover.exe file from the installation diskette 

ISELDRV V3.2. Set the key-operated switch to TEST mode. The COVER key ➅ should now 

light; open the cover only if this key lights. 

To enable the following functions, make sure that the EMERGENCY STOP button is 

unlocked. Return to AUTOMATIC mode. 

- Close the cover and press the POWER key ➁ to turn on the output stage; the push-button 

must light. 

- The spindle motor can be turned on in AUTOMATIC mode only if the POWER key lights, 

the cover is closed and locked and if the software communicates with the machine. 

- During the machining, the cover is locked. You can only open the cover if the machine has 

been stopped, the spindle motor is switched off, the machine is in home position and the 

software allows the cover to be opened (COVER key lights). 

- To open the cover, push the COVER key. If the cover has been closed, it will be locked 

automatically. To start the machine, push the START key again. 

Key-operated switch 

To test the program, you can nevertheless open the cover during operation if you turn the 

key-operated switch to TEST. 

The working program stops the drive axes immediately and goes on running if you hold 

down the START key. 

This key may only be used by expert and authorised personnel since after opening the 

cover no more protection against moving machine parts is provided. 

14


5 Cleaning / Maintenance 

Open the cover before switching off the machine. Then, it is no more possible. 

Before you start any cleaning or maintenance work, trip the main switch and remove the 

mains plug to avoid the system from being restarted. 

Remove all chips from the machine at regular intervals using a broom or vacuum cleaner 

(no compressed air). This 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 come with long-term lubrication. Depending on the load, 

you should grease the shaft guides and drive shafts approx. every 500 ... 1,000 operating 

hours. Use standard roller bearing grease. 

The shaft guides and shafts come lubricated with GP00/000F-20 sodium soap grease to 

DIN 51 502. 

If you use oil, lubricate every 100 ... 200 operating hours. 

To lubricate the drive axes, first do a reference approach, then open the cover and only 

now switch off the machine. 

15


To lubricate the Y axis, move* the T-slot 

plate completely to the back and then 

remove from the Y axis (six screws). 

Remove the plastic plug beneath and 

lubricate through the lubricating nipple, 

which now becomes visible. 

Access to the guide rails is provided 

through the sealing lips. 

S 

To remove the cover sheet of the Y axis, 

loosen all fastening screws. 

S marks the access to the lubricating points in all drawings. 

To lubricate the X axis, move the 

carriage to the left*, remove the 

plastic plug on the left-hand side of 

the machine and lubricate through 

the lubricating nipple, which now 

becomes visible. 

Access to the guides rails is provided 

through the sealing lips. 

S 

First, remove the spindle motor from the Z axis, remove 

the three plugs and push the carriage completely down*. 

Apply some oil to the guide rails through the two side 

holes. 

The lubricating nipple for the drive is now behind the front 

opening. 

* If the machine is switched off you can 

move the carriage manually. 

16


6 Troubleshooting 

Fault Cause Remedy 

Equipment cannot be turned on No mains power Check mains fuse, 

Check mains connection 

Mains switch not turned on 

Fuse defective (mains supply) 

Turn on mains switch 

Pull mains plug 

Replace fuse (see below) 

POWER key does not function Cover not closed Close cover 

Emergency Stop not unlocked 

Fuse defective (mains supply) 

Hardware limit switch activated 

Driver not loaded 

Unlock Emergency Stop 

Pull mains plug 


Go to home position 

install driver 

Software does not work correctly Equipment not turned on Turn on equipment (main switch) 

Output stage not turned on 

Driver not loaded 

Connection not correct 

Turn on output stage (POWER key) 

Install driver 

Check cable connections 

Spindle motor does not work Not enabled by software System reset and go to home position 

Adjustments in the software 

not correct 

Check spindle settings 

Scaling of axes Leadscrew pitch does not corres- Change the leadscrew pitch in the 

not correct pond to the setting in the software driver program to 4 or 10 mm 

Output stage does not function Fuse defective (power block) Pull the mains plug 


17


Replacing the Fuses 

Pull the mains plug before changing any fuse! 

Access to the main fuses of the machine ➅ is provided from the outside. They are located 

directly beside the mains plug. 

To replace the other fuses, 

remove the rear panel. There you 

find: 

will 

➀ 

➁ 

➂ 

➃ 

➄ 

➅ 

➆ 

Power output stages 

Power block 

Terminal board 

Frequency converter 

Terminal block 

Mains input with main switch 

SK module 

Positions of the fuses ... 

... at mains input ➅ ... in the SK module ➆ ... in the power block ➁ 

2 x 10 A, HBD slow-blow 2.5 V/ 250 V 4 x 10 A/80 V 

Triangular wrench 

For special cases (if a switch is defective or in case of power failure etc.), you can open the 

cover interlock manually using the triangular wrench. 

1. Switch off the machine and lift the machine. 

2. Remove the four screws and the shield in the bottom plate. 

3. Insert the triangular wrench into the interlock 

from below and turn it around half a turn to the 

left without applying excessive force. 

Do not operate the 

machine in this state. 

Hole to the keyswitch (from below) 

18


7 Technical Specifications / Accessories 

7.1 Mechanics 

CPV 4030 

Dimensions w x d x h [mm] 710 x 820 x 750 

Traversing ranges X axis [mm] 395 

Y axis [mm] 300 

Z axis [mm] 110 

Passing height [mm] 150 

Clamping table [mm] 375 x 600 

T-slot raster [mm] 25 

Approx. weight [kg] 95 

Sound pressure level 

< 75 decibel (A) 

Mains rating 

230 V, 50 Hz, 16 Amp 

Driving motor 

120 W each 

Main spindle motor 

500 W 

Fusing 

power input 2 x 10 Amps, slow-blow HBD 

Earthing corresponds to protection class I. 

EMC test to EN 55011-B and EN 50082-1 

Subject to changes without prior notice 

7.2 Electrical Components 

The main electrical components are: 

- Power block PB 600-R 

- Servomotor power output stage PVM 0810 

- Safety circuit module SVM-1 

- Terminal block BIG 1608 

- Frequency converter 

- Control computer (external, not included in the standard extent of delivery) 

- Servomotor control card UPMV 4/12 

- Two multi I/O cards 

The complete system (machine and control computer) complies with 

EN 50081-1 and EN 50082-2 EMV. 

19


PB 600-R Power Block 

• 600 VA toroidal-core transformer with temperature control 

• Electronic starting current limiting 

• Overvoltage protection of motor output voltage 

• Auxiliary voltage I + 24 V/2 A 

• Auxiliary voltage II + 24 V/1 A (safety circuit) 

• Closed sheet steel housing L x W x H: 220 x 150 x 140 mm 

• Contacting via connectors 

The PB 600-R power block is a compact power supply unit for power output stages/ 

controllers. The power block provides both an non-stabilised intermediate-circuit voltage 

as an operating voltage for the power output stages and a + 24 V stabilised voltage for 

the supply of limit switches and sensors. 

Another + 24 V power circuit is provided in the power block to perform control and 

monitoring functions of safety-relevant components and to carry out emergency stop 

cut-out of the motor voltage. 

The PB 600-x power block is type-tested and is subject to a production control by the 

VDE (VDE Test Certificate 6224). 

PB 600-R power block 

20


PVM 0810 Power Output Stage 

• 3 or 4 UMV 10 servomotor power boards 

• Set-value specification: ± 10 V (current control) 

• Evaluation of encoder signals to RS 422 

• Protective circuits for overvoltage, overcurrent, overtemperature 

• Front-panel displays for operation, fault and output stage shutdown 

• Control input via 50-pin ribbon plug connector 

(compatible with the UPMV 4/12 servomotor card) 

• Supply voltage input and motor output via board plug connector 

• Monitoring of 8 limit switches in the drive axes 

• Signal input for function monitoring of the servomotor control card 

(readiness for operation of the control computer, watchdog) 

PVM 0810 Servomotor power output stage 

21


SVM-1 Safety Circuit Module 

• Two operating states that can be selected using a key-operated switch 

- AUTOMATIC mode 

- Test mode 

• Control of the cover function 

• Enabling of main spindle drive 

• External operating console with the following function keys: 

- EMERGENCY STOP 

- POWER key (power output stage ON) 

- Key-operated switch (mode selector switch) 

- ACKNOW key (confirmation key) 

- START key (program start) 

- STOP key (program stop) 

- COVER key (cover control) 

• Display of the operating states by a 10-digit LED display 

• + 24 V power supply (external) 

The safety circuit module monitors the safety-relevant components of the controller and 

extends the operating facilities of the machine by mode selector switches and control 

keys. 

SVM-1 safety circuit module 

The function of the safety circuit module is only ensured if all control and operating units are 

connected (safety switch etc.). 

22


BIG 1608 Terminal Board 

• Signal and terminal-compatible with the isel multi I/O card 

• Status display of the inputs/outputs by LEDs 

• Connection of the inputs/outputs via modular terminal blocks 

• Analog output for speed control of a main spindle drive 

• Power supply by integrated primary switched-mode power supply (60 VA) 

The terminal board serves as an adaptation aid to the 37-pin Sub D connector of the multi 

I/O card. 

The signal inputs and outputs of the multi I/O cards are provided to the corresponding 

connector X1 of the terminal board using a 1:1 connection line and connected there to a 

user-friendly screw-type terminal connector. 

At the same time, the module possesses LED displays to display the state of the inputs 

and outputs. 

For power supply, the module requires a +24 V d.c. voltage. 

This is provided by an integrated primary switched-mode power supply (60 VA). 

other 

specifications 

outputs 

inputs 

inputs 

60 VApower 

supply 

connection 

multi I/O card 

BIG 1608 terminal board 

23


Frequency Converter for Main Spindle Drive 

The main spindle drive consists of the following components: 

- spindle motor and 

- frequency converter. 

The spindle motor is a two-pole asynchronous motor with an output of 500 W (S6-40 % 

operation). Controlled by a frequency converter, the motor is designed for a max. speed of 

24,000 rpm. 

For tool mounting, collet chucks ranging from 3 mm to 6.35 mm (1/4”) are provided (see 

“Accessories”). 

The motor is controlled by a 1,100 VA frequency converter integrated in the CPV. 

To control speed and direction of rotation, the signal inputs of the converter are wired with 

the terminal board and the SK module of the machine. This ensures that apart from the 

speed setting (by the analog output of the connected multi I/O card), the handling of the 

EMERGENCY STOP situation is also provided. 

The power supply of the converter (AC 230 V) is provided via the mains input plug of the 

CPV. 

Converter for the main spindle drive 

24


Control Computer 

Housing 

• solid sheet steel system rack for PC components 

• 19" drawout-unit design (4 HE) 

• alternatively: powder-coated aluminium half-shell housing 

(anthracite), dimensions W x H x T: 475 x 186 x 410 mm 

Configuration • Processor Pentium (min. 200 MHz) 

• RAM 

• Hard disk (optional) 

16 MB 

min. 2.1 GB 

• Graphics card PCI, (4 MB ) 

• Floppy drive 

• CD ROM drive 

• Ports 

• Power supply 

3.5"/1.44 MB 

24-fold 

2 serial, 1 parallel 

200 W (TÜV) 

The control computer is configured using the components available at the date of delivery. 

The features listed above are the minimum system requirements. 

Opened control computer (desk-top housing) 

a) UPMV 4/12 servomotor control card 

b) Two multi I/O cards 

The isel control computer (not included in the standard extent of delivery) currently consists of 

a compact Pentium computer with hard disk, floppy drive and PCI graphics card. The solid 

sheet steel housing provides high operational reliability of the system and ensures the 

compliance with the existing EMC regulations (noise emission, noise immunity). 

25


Multi I/O Card (2x) 

• PC plug-in card (l = 250 mm) for ISA slot 

• 16 opto-isolated signal inputs (+ 24 V, industry standard) 

• 8 relay outputs (+ 24 V switching, 300 mA) 

• Opto-isolated analog output (± 10 V) 

• Card output via 37-pin Sub D connector 

The multi I/O card with 16 inputs and 8 outputs (as a PC plug-in card) is tailored to the 

needs of binary-data acquisition and exchange. 

The PC card is 250 mm long and can be inserted into any PC or industrial computer 

using a 16-bit ISA bus connector. 

The settable basic address provides both a combination with other PC plug-in cards and 

a cascading of several multi I/O cards. 

Multi I/O card 

For more information, refer to the Readme file contained in the provided software. 

26


UPMV 4/12 Servomotor Control Card 

• 4 independent axis processors 

• 32-bit set-value registers, acceleration registers 

• 32-bit position measurement 

• Programmable 16-Bit PID controller, sampling interval 0.35 ms 

• 12-bit D/A output (± 10 V speed set value) 

• 8 signal inputs for limit switches (opto-isolated) 

• 4 signal inputs for reference/zero-point switches (opto-isolated) 

• Signal input Output Stage Fault (opto-isolated) 

• Signal input Enable Limit Switch (opto-isolated) 

• Signal output Output Stage Shutdown (opto-isolated) 

• Signal output Enable Limit Switch (opto-isolated) 

• Connection via 50-pin ribbon connector 

The UPMV 4/12 servomotor control card is a PC plug-in card (approx. 380 mm long) for the 

selection of up to four d.c. servomotors. 

- It integrates four independent, digital axis processors, type National LM628. 

- Apart from the function blocks of the PID position control of the d.c. servomotors and setvalue 

generation, the processors also include the position measurement of the numerical 

axes by evaluating the pulse sequences using the incremental rotary encoder flanged on 

the motor. 

To suppress any line-borne interference, the signals on the rotary encoder side are 

converted to RS422 using symmetric signal drivers. 

The control card as an output to the external power output stage provides a speed set 

value of 

± 10 V. A monitoring of the limit and reference switches in the servosystem is by evaluating 

opto-isolated + 24 V signal outputs. 

- In addition, the card has an input for fault messages of the output stage and outputs to 

short-circuit the limit switches, to switch off the power output stages and for safety 

shutdown of the PC card. 

- To install the card, a 16-bit ISA slot is required in the control computer. 

UPMV 4/12 servomotor control card 

27


7.3 Starting Up the UPMV 4/12 

7.3.1 Base Address 

The communication of CPU and PC plug-in cards is carried out by data exchange within a 

defined address window of the adopted AT bus. This requires the active address range on the 

corresponding PC plug-in card to be set accordingly. 

To this aim, various address spaces are predefined for the appropriate application cards. 

For user applications, normally the address range from 300h to 36Fh is provided. 

X1 - output connector 

J1 - base address jumper section 

J2 - interrupt jumper section 

The setting of the active address range on the UPMV 4/12 is carried out using the coding 

section J1. The following assignment is applicable: 

J1.1 J1.2 J1.3 J1.4 J1.5 J1.6 Base address 

(A9) (A8) (A7) (A6) (A5) (A4) set 

OFF OFF ON ON ON ON 300h - 31Fh 

OFF OFF ON ON ON OFF 310h - 31Fh 

OFF OFF ON ON OFF ON 320h - 32Fh 

OFF OFF ON ON OFF OFF 330h - 33Fh 

OFF OFF ON OFF ON ON 340h - 34Fh 

OFF OFF ON OFF ON OFF 350h - 35Fh 

OFF OFF ON OFF OFF ON 360h - 36Fh 

ON = Jumper plugged OFF = Jumper open Standard setting 

Please make sure that address ranges of different PC plug-in cards do not clash. 

7.3.2 Interrupt Source of the Servomotor Control Card 

Hardware Interrupt 

The driver software (motion module) to the servomotor control card requires a defined 

hardware interrupt during interpolation mode. 

To avoid double assignment of different PC cards, the UPMV 4/12 provides the choice from 

two interrupt sources. To this aim, activate one interrupt source and plug jumper J2 as 

indicated in the Table below. 

J2.1 IRQ10 

J2.2 IRQ11 (standard setting) 

J2.3 IRQ12 (cannot be used) 

J2.4 IRQ13 (cannot be used) 

28


Software Interrupt 

The interrupt address 78h is used as the software interrupt (described in the start-up program 

more in detail). 

For more detailed information on the base address settings, refer to the Manual of the 

UPMV 4/12 servomotor control card (p. 12ff). 

7.3.3 Signal I/O 

In conjunction with a PVM 0810 power output stage, the inputs/outputs provide various 

functions. In the UPMV 4/12 servomotor control card, the inputs are controlled and 

monitored from two input ports and one output port. 

Input port 1: (address 30Ch) 

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 

Reference switch 

Fault Axis 4 Axis 3 Axis 2 Axis 1 

Output stage 

Input port 2: (address 30Eh) 

Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0 

Limit switch 1 Limit switch 2 

Axis 4 Axis 3 Axis 2 Axis 1 Axis 4 Axis 3 Axis 2 Axis 1 

The port addresses specified are correct provided you use the control card with the base 

address 300h. 

If you have set a different base address, you must make appropriate adaptations. 

The individual signals are: 

- Signal input of limit switch 

To ensure the maximum traversing travels and thus to provide protection of the connected 

axes, limit switches are used in the servosystems for the end positions of the axes. 

If one of these switches is actuated during operation, the monitoring circuit will switch off 

the power supply of the power output stages. At the same time, this operating state is 

transmitted to the servomotor control card in the control computer. Evaluation by software 

is possible by reading the input port 2 (base address + 0Eh). 

29


1N4148 

2k2 

X1.xx 

Limit switch 

(+ 24 V switching) 

X1.18 

GND 

Signal input of limit switch 

Programming example: Reading of signal input 

Base address 

300h 

Address of input port 2 

30Eh 

Input statements in Borland C inportb(0x30E) 

If the limit switch is properly installed and operates correctly, the data bits are 0. An 

activating or not connected switch will set the corresponding data bit to 1. 

- Reference switch signal input 

The numerical axes can be traversed to their zero or reference point by evaluating the 

reference point signal inputs. When approaching the reference point, all positioning 

commands will refer to this machine zero point in absolute dimensions or to a zero point 

later defined via software. 

2k2 

X1.xx 

Reference switch 

(+ 24 V switching) 

1N4148 

X1.18 

GND 

Reference switch signal input 

Programming example: Reading of signal input 

Base address 

300h 

Address of input port 1 

30Ch 

Input statement in Borland C inportb(0x30C) 

If the reference switch is installed correctly, the data bits will indicate the values 1 to 4; an 

activated or not connected switch will set the corresponding data bit to 1. 

30


- Fault at output stages (pin 19) 

In case of a malfunction, the power output stages UVE 8012 will generate an error signal, 

which is signalled by the opto-coupler output Output Stage Fault. 

This fault message is acquired in the servomotor power output stage together with the 

faults to follow and are transmitted to the UPMV 4/12 control card. 

The following signals/voltages are monitored as possible error sources: 

- Output stages switched off by software 

(signal output Output Stage Shutdown of UPMV 4/12 set) 

- Shutdown of one power output stage by overtemperature 

- Shutdown of one or several output stages by an overcurrent fault of the output stage 

transistors 

- Missing supply voltage (operating voltage + 70 V) not turned on) 

- Missing or defective/interrupted connecting line from the servomotor power output 

stage to the servomotor control card in the control computer 

The error message can be evaluated by the software by reading the address (base address 

+ 0Ch, bit 4). 

- Safety shutdown (pin 40) 

To ensure that the safety shutdown of the power electronics operates if the computer 

“bombs”, after the control computer has been switched off or in case of a run-time error, 

the UPMV 4/12 has a so-called watchdog monitoring. 

The respective output (pin 40 of the 50-pin ribbon connector) is active (+ 24 V), as long as 

the readiness for operation is ensured. The output is open in case of a fault at the control 

unit. 

- Output stage shutdown (pin 16) 

For start-up or control and measuring purposes, it can be reasonable to make the output 

stages of the servocontroller dead, thus blocking the control response of the position 

controller of the numerical axes. To this aim, the UPMV 4/12 has the signal output Output 

Stage Shutdown. 

The output is activated/deactivated by the control software. In normal mode, the output is 

active and results in that the corresponding signal input of the output stage is also switched 

on (enabled). 

If the output is inactive or open, the output stages are made dead. 

If the output stages are dead, the Fault LED in the front panel of the UVE 8012 power 

output stage lights. 

31


- Enable limit switch (pin 43) 

The safety system of the servocontrollers is based on a series circuit of controls, monitoring 

and limiting devices, which enables the motor voltage via a safety relay. 

If any limit switches are activated due to a misbehaviour of the control system or the 

mechanics or due to an operating error, the supply voltage of the output stages is 

switched off and remains switched off until the error is eliminated. 

In such a case, you must traverse the axes back to the working area prior to any further 

machining. To this aim, the operating mode Activate/Deactivate Safety Circuit is provided 

in the control system. This function is used to activate the control circuit Enable limit switch 

output. This will enable you to restart the power output stages and clear the limit switches 

in Teach-in mode. 

If you have carried out this action, deactivate the output to return to normal mode. 

In this operating mode, observe, in particular, all precautions and safety measures of the 

accident prevention rules. 

Improper operation of the control unit in this operating state may damage or destroy the 

machine! 

For additional information on the UPMV 4/12, refer to the UPMV 4/12 Manual 

32


7.4 Evaluation of Limit and Reference Switches 

7.4.1 Limit Switches 

In drive systems, limit switches are used to limit the maximum traversing travels of the 

numerical axes, preventing the mechanical and electronic control components from 

damage. 

The switches (min. and max. position) directly control the safety functions of the 

controller. At the same time, this information is provided to connector X1 as the + 24 V 

signal. 

To visually check the switching position of the limit switches, LEDs are provided on the 

connecting board of the PVM power output stage, which light if the corresponding limit 

switch is correctly connected and not actuated. 

Pilot LEDs of limit switch 

7.4.2 Reference Switches 

In numerical axis drives, reference switches are used to determine the machine zero. 

The evaluation of the switches is provided by a higher-level control unit, e.g. the servomotor 

control card UPMV 4/12. 

If the reference point has been approached, all positioning instructions will refer to this 

zero point in absolute dimensions. 

33


7.4.3 Enable 

The control signal “Enable” is used to switch off the monitoring circuit of the limit switches for 

a short time. This allows you to clear the drive control via software with the limit switch 

approached. 

The control signal switches off the safety monitoring of the limit switches. Please watch the 

connected devices with reference to personal protection and operational reliability of the 

machine. 

To provide optical monitoring, LED3 in the PVM 0810 power output stage lights up if the 

signal is switched on. 

7.4.4 Safety Shutdown 

The control signal signals readiness for operation of control computer and plug-in card to 

the power output stage. 

An active signal allows the power supply of the power output stages to be turned on. As a 

check-back, LED2 on the rear panel of the power output stage lights up. 

For more detailed information on the check-back signals, refer to the description of the PVM 

0810 servomotor power output stage or the UPMV 4/12 servomotor control card. 

34


7.5 Connectors 

Pin assignment of the connectors to the control system of the CPV without integrated 

electronics. 

Motor lines (➀ to ➃ in the illustration on page 9) 

For safety reasons in PC CNC servo controllers 

(motor output, power unit and servo motor) the 

coding of the connector ist based on code 7 

(reference figure on the left). 

1 = + U motor (red) 

2 = - U motor (black) 

3 = limit switch 1 (black) 

SL = PE motor cable shielding , frame 

4 = + 24 V brake, fan (option) (yellow) 

5 = GND encoder (brown (red/black + shield)) 

6 = GND brake (yellow) 

7 = limit switch 2 (yellow) 

8 = Vcc encoder (red) 

9 = reference switch (option) 

10 = encoder phase / A (blue/black) 

11 = encoder phase / B (yellow/black) 

12 = encoder phase A (blue) 

13 = encoder phase B (yellow) 

14 = + 24 V (auxiliary voltage for switches) (white/yellow) 

35


Control lines 

9-pin sub D connector, START and STOP key (➄ in the illustration on page 9) 

Signal Pin Pin Signal 

User input 1 6 - 

User input 2 7 + 24 V-I/O 

Start 3 8 + 24 V-I/O 

Stop 4 9 GND 24 V-I/O 

connected 5 

Sub D-9 connector, cover switch (= H) (➅ in the illustration on page 9) 


H coil + key on 1 6 GND 24 V fuse H coil 

H pin 22 2 7 GND 24 V fuse 

+ 24 V fuse H pin 2 3 8 GND 24 V fuse 

H pin 12 4 9 GND 24 V fuse 

+ 24 V-I/O H pin 11 5 

Sub D-15 connector, POWER/Emergency stop switch (➆ page 9) 


ON (emergency stop loop) 1 9 ON (emergency stop loop) 

Emerg. stop (emerg. stop loop) 2 10 Lamp (in the ON button) 

connected 3 11 Lamp (in the ON button) 

+ 24 V fuse 4 12 + 24 V fuse 

Emerg. stop (emerg. stop loop) 5 13 + 24 V I/O (2-level key-switch) 

Key-operated switch 6 14 + 24 V I/O (2-level ON) 

ON (2-level info) 7 15 + 24 V I/O (2-level emergency stop) 

Emergency stop (2-level info) 8 

36


7.6 Charts and Tables 

7.6.1 Block Diagram of Safety Circuit 

Auxiliary voltage II 

+ 24 V 

Emergency Stop 

Emergency Stop 

function 

(Remote) 

Limit position 1 

axis 1 


axis 1 

Cut-out 

limit switch 

(relay S9) 

Key switch SK 


axis 4 

PC-contact 

Watch-Dog 

(Relay S10) 

POWER key 

POWER key 

(Remote) 

Block diagram of safety circuit 

37


8 Accessories 

You can order the following accessories for the CPV: 

Order no.: 

- Collet chucks for the spindle: e. g. 239 110 3000 

1 to 5 mm in steps of 0.5 mm steps, 6 mm and 1/8" 

- Additional mounting hardware for the T-slot plate e. g. 290 001 

- Drill and milling cutter set, shaft 3 mm / 3.175 mm 400 100/400 200 

7 drills (0.5 - 3 mm), 8 milling cutters (1 - 3 mm and/or 1/8"), 2 chisels 

- Working area illumination 280 1XX 9004 

- Suction apparatus 280 1XX 9001 

- Vacuum cleaner 425 005 

- Engraving spindle (25,000 rpm and/or 20,000 rpm) 421520/421503 0001 

- Engraving pad 280 1XX 9003 

- Sprinkling/chilling appliance 280 1XX 9002 

- Rotary axis e. g. 263 003 0001 

- Grease gun 931 170 

Make sure that all accessories are correctly installed and observe the relevant standards and 

safety regulations. 

For the mounting and operating instructions of the accessories, refer to the Appendix. 

For further information and/or purchase orders, please contact the 

- Technical Consulting Dept. +49-6672-898-211 to -213 or to the 

- Sales Dept. +49-6672-898-311 to 313, fax +49-6672-898-176. 

38


9 Appendix 

39


10 Service waybill (please, also consider the notes to the next page) 

Sender 

Company 

Customer No. 

Contact person/Dept. 

Phone 

Postal address 

Fax 

Return to 

Invoice No./ 

Qty. Item number Designation Delivery Note No Serial number 

(please add copy) 

Cause of the complaint 

a) Financial complaint m wrong delivery m variance of quantity 

m ________________________________________ 

b) Technical complaint 

Error description 

When does the fault occur? 

m permanently 

m sporadic 

m temperature dependent 

m after ___ minutes of operation 

Was the item already in use? 

m has not yet been used 

m defect during commissioning 

been in use for __ months 

Date 

Signature 

40


Please observe the following if you return any goods: 

1. Warrantee proof 

To prove your warranty claim, a copy of the purchase bill or of the delivery note is 

required. If this proof is missing, we will return the good unprocessed carriage forward 

against a charge. 

2. Error description 

In case of products arriving at our plant without precise error description (”Defective” or 

”For Repair” is not sufficient), we are entitled either to carry out an error diagnosis with 

costs or to return the unrepaired product carriage forward against a service charge. 

3. Unjustified claims 

In case of unjustified claims (no fault can be detected, probably an operator error), the 

product is returned carriage forward against a service charge. 

4. Packaging 

We can only accept returned products in the original isel or equivalent package. The 

warranty claim is endangered by missing original or inappropriate packing. Resulting 

transport damages will annul the warranty claim. 

5. Third-party manufacturer products 

Products not delivered by us are returned unrepaired carriage forward against a service 

charge. 

6. Tarnsport charges 

iselautomation will bear the carrying charges for return deliveries resulting from 

warranty claims. Any other carrying charges shall be borne by the sender. For 

organisational reasons, we will not accept any goods delivered to us carriage forward. 

7. Sales conditions, delivery conditions, and terms of payment 

As for the rest, the conditions of sale and delivery, as well as the terms of payment of 

iselautomation are valid without change. 

41


Key word list 

A 

accessories 9, 19, 38 

AUTO 12 

axis positions 11 

C 

Certificate of Conformity 39 

chilling appliance 38 

clamping assembly 9 

cleaning 15 

collet chucks 24, 38 

connecting Lines 10 

connectors 35 

control computer 25 

coordinate System 11 

COVER 12, 14 

D 

dimensions 7, 19 

drive axes 15 

E 

EMC 19 

Emergency Stop 12 

enable 34 

engraving pad 38 

engraving spindle 38 

extent of delivery 7 

F 

frequency converter 18, 24 

fuses 18 

G 

grease gun 38 

H 

hand lever 9 

home position 11 

I 

isy-CAD/CAM 13 

J 

jumper 28 

K 

key-operated switch 12, 14 

L 

limit switches 33 

lubricating nipple 16 

lubrication 15 

M 

machine zero point 11 

main spindle drive 24 

main switch 18 

mains input 18 

maintenance 15 

mounting set 9 

multi I/O card 26 

P 

pin assignment 35 

POWER 12 

power block 18, 20 

power output stage 18, 21 

PRO-DIN 13 

PRO-PAL 13 

R 

reference point 11 

reference switches 33 

REMOTE 13 

roller bearing grease 15 

rotary axis 9, 38 

S 

safety circuit 37 

safety circuit module 22 

safety shutdown 34 

sealing lips 15 

SK module 18 

spindle motor 24 

START 12 

Start-Up 11 

STOP 12 

stop bars 9 

suction apparatus 38 

system requirements 11 

T 

technical consulting 38 

technical specifications 19 

terminal block 18 

terminal board 18, 23 

TEST 12, 14 

transport 9 

triangular wrench 9, 18 

troubleshooting 17 

U 

UPMV 4/12 27 

V 

vacuum cleaner 38 

W 

working area illumination 38 

workpiece zero point 11 

X 

X axis 16 

Y 

Y axis 16 

Z 

Z axis 16 

42

isel-CNC Machine - Bedienungsanleitungen / Manuals isel

You also want an ePaper? Increase the reach of your titles

Delete template?

Save as template?