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Commissioning manual STANDARD

for the service technician


With electrical and
pneumatic / hydraulic diagrams for:
 KAB – Wiring harnesses STANDARD
 WDF – Wall penetrations STANDARD
 OEM cabling
for pL LEHMANN product line 500 rotary tables
with PGD gear unit technology

www.lehmann-rotary-tables.com
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GENERAL INFORMATION

Table of Contents

1 GENERAL INFORMATION ......................................................................................... 3

2 ASSEMBLY.............................................................................................................. 13

3 COMMISSIONING................................................................................................... 23

4 TECHNICAL INFORMATION..................................................................................... 51

5 TROUBLESHOOTING............................................................................................... 68

6 DESCRIPTION OF THE WALL PENETRATIONS «WDF» .............................................. 70

7 PNEUMATIC/HYDRAULIC DIAGRAMS – STANDARD AND OPTIONS......................... 79

8 DIAGRAMS OVERVIEW - ALL ELECTRICAL DIAGRAMS ............................................. 83

9 ELECTRICAL – STANDARD CABLING DIAGRAMS ...................................................... 86

10 DIAGRAMS FOR OEM ELECTRICAL CABLING ......................................................... 131

11 CONTACT ............................................................................................................. 153

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GENERAL INFORMATION

1 GENERAL INFORMATION
1.1 Document History
Ix(1) Date of issue (2) Page What of
23 2016-06-21 85 # WDF.Fx-R1x-2 korrigiert. Neu Index 3. Bm
23 2016-09-12 106 # KAB.Y2x-x.x-R1x-2 neu eingefügt Am
23 2016-09-26 129 # STE.DMbw Schema nur betr. Stückliste korrigiert. Kabel jetzt auch dabei. Am
141 # 121.026a Schema nur betr. Stückliste korrigiert. Kabel jetzt auch dabei.
24 2016-10-07 # Index auf 24 gestellt, damit Dossier laufender Aufträge erneuert wird. Lw-frö
24 2016-12-15 104 # Schema KAB.M2-x.x-R1x-2 eingefügt für Auftrag vor der Auslieferung Am,bm
25 2016-12-21 102-103 # Schemas KAB.Fx-x.x-Rx Schlauchüberlängen gelöscht zugunsten 029-0009. Frö
145 # Schema MATSUURA eingefügt
68 # Bohrschablone hat neu Ø-Angabe bei Luft und Oel.
36 # Mit ACHTUNG auf möglicherweise falschen Ref.-pt. hingewiesen.
47-56 # Technische Informationen verbessert/erweitert.
80 # Tabelle von Schemas erstellt, die UND/ODER in anderen DOK's sind.
123 # Die Grafik zum selbst Herstellen von KAB erneuert.
133 # Bei STE.DMbw Kontur WMS gelöscht. Mehrere im Einsatz.
26 2016-12-22 107 # In KAB.M1x.x-R1-2 bei X2A1x Pin K u L war Beschriftung verkehrt. As
133-134 # In DMB-1.7m-Schemas den Schirm bei 4p. entfernt, Nrn korrigiert. Lw
65 # Neu ALLE OEM's in Kap. 10 in IHV aufgeführt. Frö
59 # Spindelgesichter neu dargestellt, gleich wie in ACA, und verschoben in Tech.Info frö
27 2017-02-08 91 # WDF.M2-R1x-S-2 ist neu dazugekommen. Hl
109 # KAB.M2-x.x-R1x-2 wurde Enc äu.Schirm eigenständig aufgelegt wg möglicher Störungen As
# KAB.M1-x.x-R1x-2 wurde gelöscht. Wenn R1, dann EQN. Am/hl
27 2017-02-13 91 # WDF.M2-R1x-S-2 getauscht. Jetzt mit Bild. Frö
28 2017-03-09 90-91 # Bei WDF.Fx-R1xx-S-2 und WDF.M2-R1x-S-2 Brücken für Axis present. As/frö
# Hinweise auf DOK-0301 Wartung eingearbeitet. Chm/hl
28 2017-03-13 141 # Auf Schema Steckerbilder getauscht. X2A… gehört oben. Te
110 # Steckerbeschriftung verdeutlicht auf Schema KAB.MI1-x.x-R1x-2 as
29 2017-04-05 42 # Bild GLA.HYD-vario erneuert. Frö
150 # Schema KAB.OK… kommt dazu. Wohl nur vorübergehend. Hl
70 # Bei Nockenring reinigen die Markierung richtig dargestellt. Zm
44ff # SCHRITT 11-12 DT-Anlage ausrichten erneuert aufgrund Vorlage stl Hl
126-127 # Schutzschlauch selbst und STE erneuert Frö
29 2017-04-27 90-94 # Beschriftung Kabel beidseits: WDF.Fx-R1x-S-2 (Kap. 9.1.5) As / frö
# Neue Länge abmanteln bei Leistung: WDF.M1-K-2…, WDF.M2…, WDF.MI1… (Kap. 9.1.2-4)
# Beschrift. Kab. beidseits + neue Länge abmant. bei Leistung:WDF.M2-R1x-S-2 (Kap. 9.1.6)
97 # KAB. … w-K8(R1) (Magnescale RU77-Y) Belegung korrigiert. Bm/as
30 2017-07-03 110 # Kapitel 9.5, Schema KAB.Rx-x.x-R1… neu mit Schutzschlauch über Oel-Luft. Fehler frö Frö
154 # 2 KAB….DMd nur noch in Tab der OEM-Schema erwähnt. Sind in DOK-0215 und -0279 As
89ff # In WDF-Schemas neuen SIEMENS Leistungsstecker eingefügt. Div. grafische Verbess. As/frö
121, 113 # Adapter Motor Leistung ist neu Teil der Baugruppe Motor. Am
42 # Entlüften Gegenlager bei Tx- besser dargestellt Chm/hl
43 # SCHRITT 11: Ref u Umkehrspiel erfass u parametr anders dargestellt Chm/hl

 Change index and date are entered in each footer. …__DOK-xxxx-xx.00 (1)_...._YYYY-MM-DD (2).docx

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GENERAL INFORMATION

1.2 Meaning of signal words and symbols used


pL LEHMANN rotary tables are used as a rotary axis in the enclosed machining compartment of machine
tools. Despite having been manufactured in compliance with the generally accepted rules of design and
manufacture, a rotary axis can pose hazards.
The following symbols, signal words and the text that follows draw attention to potential hazards to life
and limb. These safety instructions are important and must be observed.
However, it is also important to us to prevent possible property damage and also make suggestions for
optimal use with the signal words WARNING and NOTICE.

Markings Meaning of Symbol and Signal Word


Indicates a potentially dangerous situation that could result
WARNING in death or serious injury.
Indicates a potentially dangerous situation that can result in
CAUTION minor injury.
Indicates a potentially dangerous situation that can result in
ATTENTION damage to property.
Highlights useful tips, recommendations and information for
NOTE efficient and trouble-free operation.

1.3 Signs and Labels


There are no permanently attached signs or labels on pL LEHMANN rotary tables regarding the safety of
individuals and material.
Nevertheless, this label with safety instructions is attached to one of the eyebolts on each piece of
equipment prior to shipment:

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GENERAL INFORMATION

1.4 Product Documentation 500 - Validity of this Document


This document is an integral part of the «BR 500 Product Documentation» as listed in the following.

1.4.1 «Packungsbeilage 500__DOK-0001»


Fixed to the rotary table, packed in a plastic bag, on a ring bolt .
Contains information for identifying the rotary table and must
therefore be retained.
Table of contents of the "Packaging insert DOK-0001":
1. Instructions for «smart doc» USB stick
2. (Instructions for download if USB stick is missing)
3. Product registration
4. EC Installation instructions for incomplete machines (MRL
2006/42/EC, Appendix II, sub. B). The system number (Serial
No.) is visible here
5. Assembly instructions (MRL 2006/42/EC, Art.13 (1) and
Annex VI)

1.4.2 Detailed «smart doc» system documentation for commissioning, operation, maintenance, …
Saved on the USB stick and attached (protected from water and dirt) to the motor cover on the system.
The data storage medium contains the following documents at a minimum:
 «ADAT - DRIVE SET-UP DATA» Techn. data for this system
 «PARA-…» Parameter list for the CNC control system supplied
 «Operating manual STANDARD, DOK-0003»
 «Commissioning manual STANDARD, DOK-0004»
 «Commissioning manual, specific», e.g. SEP brother
 Indexing accuracy report to VDI/DGQ 3441.
On T-systems, 1 report each for divider and swiveller / tilter
 «Geometry test report». Acceptance data after final assembly
 «PROFI-Catalog CNC Rotary Tables» overview. One each in
German and English
 Special drawings from customer if available
 Operating manuals for accessories such as hydraulic unit,
CNC-FANUC, etc.

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GENERAL INFORMATION

1.4.3 Website www.lehmann-rotary-tables.com


All documents and information that are not provided are available on the website.
A few examples:

 PROFI Catalog – Overview 500


www.lehmann-rotary-tables.com/en/Download/Catalogs-serie-500
Also available in print version.

 MAIN Catalog – All information 500


www.lehmann-rotary-tables.com/en/Download/Catalogs-serie-500
Also available in print version.

 Detailed Product Description


Decision-making aids, practical examples, video clips, …
Application catalogs ALMAC, BROTHER, DMG-MORI, DOOSAN, FANUC,
HURCO, etc. Facts, flyers, overviews, supplements to main catalog, …

 Machine/control system-specific manuals

The file boxes with machine tool names are empty.


However, detailed instructions for the construction, cabling, commissioning and parameterization of pL-
LEHMANN systems are available for these machines. Some even with a switchboard expansion with
«servoPACK». The corresponding instructions are provided on the USB stick of the system.

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GENERAL INFORMATION

1.5 Name plate


Mounted to the rear of the module. The data on the name plate is listed
on the «Package insert».
1. Weight
Total weight of the system. Without accessories.
2. Product
System type and version. Legend, see main catalog.
3. OEM No.
Only on customer request.
4. Serial No. (single modules)
Our internal identification number. Keep it ready when
you contact us concerning this product.
5. Serial No. (multimodule products)
On all participating modules is the same serial number engraved
in the field «Serial No.»
But the system type (Product) and the weight (Weight) is only
engraved on the tilting module.
6. Housing number (find it below the cover) For internal use only.

Example for «Serial No.» on multimodule product T1-507510.LL fixX-F1

Name plate on rotary axis Name plate on tilting axis

1.6 Product registration / Activating the warranty


Your pL LEHMANN CNC rotary table was manufactured with great care and to international standards.
The warranty for this product becomes effective upon commissioning at the end customer. The
warranty period is limited, however, as far as the machine supplier is concerned. Consult them in case
questions arise.

1.6.1 Registration requirement


The product must be registered within one week of commissioning. pL LEHMANN reserves the right to
reject warranty claims on products that are NOT registered, registered LATE or INCORRECTLY registered.
The product can be registered either by submitting the form «Activation of the warranty» in the package
insert or at http://www.lehmann-rotary-tables.com «Product registration».

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GENERAL INFORMATION

1.7 Modification, changes


Modifications and changes to pL LEHMANN rotary table systems are prohibited without our written
approval.

1.8 Safety Information


The following safety information applies to pL LEHMANN systems independently of the ultimately
binding overall documentation for the complete machine.

WARNING
Electric shock from high motor voltage.
Danger of serious injury!
 Switch off the system if flexible tubing or cables are damaged.
 Always consult the regulations of the relevant technical personnel for installation and
repairs.

CAUTION
Suspended systems can fall.
Risk of injury!
 Never stand under suspended rotary table systems during transport.
 Always use proper lifting equipment.
 Put the load down when leaving the workplace.

CAUTION
Scissor effect when moving the indexing or tilting axis.
Risk of entanglement!
 Always close safety door when working!
 Non-round parts on the rotary table spindle can behave like shears.
 When formless loads are moved on the tilting axis, varying spaces are created.
 Remove tools, measuring and test equipment, etc. out of the system's range of
movement.

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GENERAL INFORMATION

CAUTION
The EMERGENCY STOP circuit must stop the pL LEHMANN system.
Continued operation of an axis after an EMERGENCY STOP is prohibited!
 Regulations require that the drive of the rotary axis (axes) be incorporated into the
EMERGENCY STOP circuit.
 As commissioning technician, you are responsible for checking and ensuring compliance.

ATTENTION
Excessive tangential forces.
The gear unit can be damaged!
 Always activate the spindle clamping when it is at a standstill. LED lit green,
«CLAMPED».
 Avoid impact when loading / unloading.
 The spindle clamp can be released without compressed air and/or without actuation.

ATTENTION
Continuous turning can cause serious demages.
Heat accumulation in the gear box can destroi it.
The motor becomes can overheat
 Maintain a duty cycle of 20%-1min.
 Read the instructions in this regard.

NOTE
Personnel qualifications.
Only trained persons can operate the system safely and efficiently!
 Training is the responsibility of the manufacturer of the «complete machine».

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GENERAL INFORMATION

1.9 Procedures in case of accidents and malfunctions


Check list

1. Switch off the machine immediately at the Emergency Stop.


For more information on immediate stopping and preventing unintentional restart, see the doc-
umentation for the higher-order «complete machine".

2. Check immediately whether persons have been entangled or injured.

3. Enlist the help of other people if necessary.

4. Inform supervisors.

5. Call your First Aid specialist if necessary.

6. Procedure for moving spindle manually (worm drive is self-locking):

a) Unbolt the cover .

b) Insert screw / bolt , lock with nut.

c) NOTE: Direction of rotation is


reversed on the opposite side.
d) Thread size in worm gear:

Module 507 510 520 530


Thread M5 M8 M8 M8

NOTE
The documentation of the «complete machine» is binding.
For more information, refer to the documentation of the «complete machine».
 Training for how to respond in case of accidents and malfunctions is the responsibility of
the manufacturer of the «complete machine».
 The documentation of the «complete machine» provides the necessary information on
actions to take AFTER accidents and malfunctions.

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GENERAL INFORMATION

1.10 Safekeeping
Keep this commissioning manual in a safe place. It must be within easy reach for maintenance at all
times.

NOTE
Follow the instructions in the OPERATING MANUAL of the «COMPLETE MACHINE».
This commissioning manual for the pL LEHMANN rotary table is a lower-order part of the
overall documentation of the «complete machine»!
 Nevertheless, this COMMISSIONING MANUAL applies in its entirety.
 Because pL LEHMANN rotary tables always represent additional CNC axes incorporated
into a machine tool, the are considered to be an «incomplete machine» in accordance
with MRL 2006/42/EC.
 It is the responsibility of the manufacturer of the «complete machine» to prepare an
OPERATING manual in compliance with MRL 2006/42/EC. In this respect, this
commissioning manual is provided as a service.
 When an auxiliary CNC control system is used, consult the instructions for this auxiliary
control system.

1.11 Original instructions / translations


All documentation will be written in the official EU language of German and marked as "Original
instructions".
For additional languages, see www.lehmann-rotary-tables.com
The machine manufacturer or end customer is responsible for additional translations. All translations
must be marked with «Translation of original instructions».

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GENERAL INFORMATION

1.12 Machine Requirements


Integr.: For the integration of 1st/2nd rotary axis
SEP: For the integration of the pL servoPACK (Brother, Hurco)
FAN: For linking the pL «FANUC CNC control system» via
M-functions

Int. SEP FAN Requirements for CNC control/machine page (for each axis ordered)

CNC control system configured for 4th/5th axis (SW option)

AC-servo suitable for ordered motor

For the motor ordered, suitable input for the motor measuring system (encoder)

With angular position measuring system option: input suitable for WMS signal waveform

Passwords for activation of axis, position controller, M-function, etc. will be available at
commissioning

Required inputs/outputs (PNP, +24V):


1 input: Reference point switch (not needed for Brother)
1 output: «clamp» aut. spindle clamping
1 input: Clamping «clamped»
1 input: Clamping «unclamped».
2 inputs for range switches (only on swivelling / tilting axes)

Acknowledgeable M-function («Start»/«Indexing ended»)

Power source +24V approx. 200mA

Power supply 230V, approx. 1kVA

Pre-programmed PLC for the additional axes (spindle clamping, referencing, M-function
etc.). Passwords available

M-function.

EMERGENCY STOP function must be linked to the machine

The necessary diagrams, basic principles for parameter configuration etc. must be
available for commissioning.

We are unable to accept any liability for non-compliance with these


requirements/conditions. Especially additional expenditure for repeated operations and
time delays.

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ASSEMBLY

2 ASSEMBLY
2.1 Introduction ............................................................................................................................................................ 14
2.2 Check packaging and scope of delivery .................................................................................................................... 14
2.2.1 Accessories supplied loose LOZ.xxx ......................................................................................................................... 15
2.3 Transporting ............................................................................................................................................................ 16
2.3.1 Always keep the center of gravity at the bottom .................................................................................................... 16
2.3.2 Suspending correctly ............................................................................................................................................... 17
2.4 Placing, aligning the system, bolting in the correct manner ..................................................................................... 18
2.5 Installing the maintenance unit ............................................................................................................................... 18
2.5.1 Dimensions.............................................................................................................................................................. 19
2.5.2 Connections ............................................................................................................................................................ 19
2.5.3 Settings ................................................................................................................................................................... 20
2.6 For better air pressure (Option) .............................................................................................................................. 22
2.6.1 Water separator 99% Art. no. pL: 125-0991 ............................................................................................................. 22
2.6.2 Pressure intensifier ................................................................................................................................................. 22

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ASSEMBLY

2.1 Introduction
In this main chapter "Assembly instructions", the individual steps from the arrival of the system to
commissioning readiness are explained. This complies with 2006/42/EC.

NOTE
Personnel qualifications.
Trained professionals are required for the commissioning of a rotary axis!
 Training is the responsibility of the manufacturer of the «complete machine».
 pL LEHMANN offers training at different levels for service technicians.
 For first-time commissioning in your facility, we recommend commissioning by a
technician from pL LEHMANN or one of our contract partners.

2.2 Check packaging and scope of delivery


Check packaging for transport damage, damage from liquids etc.
Compare the contents of the package against the delivery note.
Accessories and small parts are packed and enclosed separately.

If damage is found or suspected:


 Accept the delivery anyway.
 Do not open. Request an immediate damage inspection
by the forwarder.

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ASSEMBLY

2.2.1 Accessories supplied loose LOZ.xxx

for EA-510/520.Ox
for T1/T2-5xx5xx
for T3/T4-5xx5xx

for LFX.510-xxxx
for LFX.507-xxxx
for M3/M4-5xx
for TF-5xx5xx

for GLA.5xx
for RFX.5xx
for M2-5xx
for EA-507
for EA-510
for EA-520
for EA-530

for EA-520
for EA-520
for EA-520
for EA-530

Air and oil


LOZ.520-CamlUNF
LOZ.520-Caml1.5

LOZ.530-Caml1.5
LOZ.5xx5xx-T1+2
LOZ.5xx5xx-T3+4

LOZ.520-Caml1
LOZ.5xx-M3+4
LOZ.5xx5xx-TF
Consisting of

LOZ.5x0-EAo
LOZ.5xx-GLA
LOZ.5xx-RFX

LOZ.510-LFX
LOZ.507-LFX
LOZ.5xx-M2
LOZ.507-EA
LOZ.510-EA
LOZ.520-EA
LOZ.530-EA
Item no.

LOZ.lo
125-0982 Ues filter regulator 1 1 1 1 1 1 1 1 1 1 1 1 1
125-0467 Oil VULCOGEAR 0.5L 1 1 1 1 1 1 1 1 1 1 1 1 1
507-0007 Clamping shoe 2 2 2
510-0007 Clamping shoe 2 2 4 4 8 2 8 10 2 8 12 10
120-3703 Steel plug M8x1.5 2 4 8 2
120-1928 Steel plug M10x1.5 2 2 2 4 8 2 4 4 2 2 4 2 2
120-2516 Steel plug M12x1.5 2 2 2 2 2
420-0257 Setscrew M16x 16 2
125.6.003 Y-distributor for Ues 1 1 1
125-0987 Y-junction 1 1 1
125-0080c Hose BU Ø4/6 5
125-0080b Hose WH Ø4/6 5
125-0081 Closing nipple 1
125-0904a Support sleeve 1
125-0695a Coupling for oil 1
125-0693 Pneumatic module 1
160-0471 Pin G5, M12x1 6
160-0471a Pin, M12x1.5 6
160-0471b Pin, UNF ½“-20 6
160-0092 Socket head screw 6 6 6
M6x12
410-0108 Setscrew M 8x 16 6 6 6
430-0343 Pin G8, M20x1.5 6
113-0040 Sock.head scr.M 8x 12 6
430-0371 Setscrew M 12x 16 6

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ASSEMBLY

2.3 Transporting

CAUTION
Suspended systems can fall.
Risk of injury!
 Never stand under suspended rotary table systems during transport.
 Always use proper lifting equipment.
 Put the load down when leaving the workplace.

2.3.1 Always keep the center of gravity at the bottom


The spindle clampings are unclamped when in an idle state.
Shaking during transport can therefore cause damage, especially to the
tilting apparatus gear unit.
For this reason, the gravitational center of the divider should always be
at the bottom for transport.

INCORRECT CORRECT

ACHTUNG
Do not loosen any screws.
The system is intrinsically geometrically aligned!
 Never loosen screws / bolts on a fully assembled system.
 Multi-axis systems in particular are already aligned and measured.
 Suspend the system only as shown below.

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ASSEMBLY

2.3.2 Suspending correctly

rotoFIX systems without table are secured with


wooden beams. Please only transport in this
manner.

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ASSEMBLY

2.4 Placing, aligning the system, bolting in the correct manner


See DOK-0003 operating manual, chapter 2 «Clamping» and chapter 3 «Aligning the system».

NOTE
Screw tightening torques.
The system can become warped and inaccurate!
 Always use a torque wrench and the specified
torques.
 The system was also assembled and measured
under these conditions.

2.5 Installing the maintenance unit


The maintenance unit is a combination of filter, regulator and pressurized lubricator with automatic
condensate discharge.
This device is included with delivery.
T-systems also require only 1 unit. In this case, air and oil hoses are then branched with Y-distributors.

ATTENTION
Compressed air at least 4 bar at flow rate of 130 L / min.
The clamping does not function below 4 bar!
 The rotary table displays the error message «clamped» and the system cannot operate.
 The error message is visible on the red LED "ERROR" on the motor cover.
 The target pressure ist 5-6 bar. A lower pressure also means a clamping force reduction.
 Make sure the air supply : The pressure must hold 4 bar min. at a flow rate of 130 L /
min.

ATTENTION
The compressed air must be dry.
High water-laden air can cripple the system!
 The maintenance unit can not cope with high humidity.
 You must ensure the the air is dry.
 For damage cause by condensation of water, we can not assume any cost.

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ASSEMBLY

2.5.1 Dimensions

2.5.2 Connections

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ASSEMBLY

2.5.3 Settings

ATTENTION
Only use pL LEHMANN oil, VULCOGEAR V5.
Otherwise, the warranty will be invalidated immediately!
 VULCOGEAR V5 was developed specifically for the very
demanding requirements of pL LEHMANN gear units.
 It must not be mixed with other products.
 Ensure that your maintenance service receives this information.

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ASSEMBLY

NOTE
Visible and available at any time.
It must be possible to remove the sight glass (oil reservoir) from below!
 It must be possible to check the oil at a glance.
 Enough light and space must be available.

NOTE
Route hoses safely.
Kinked or overheated hoses can cause malfunctions!
 Pay attention to bending radii.
 Hoses should not come into contact with hot chips or aggressive substances.

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ASSEMBLY

2.6 For better air pressure (Option)


Flawless and stable air pressure is essential to safe operation and long
system life. We recommend the following additional devices, when
needed

2.6.1 Water separator 99% Art. no. pL: 125-0991


EAMG350-F03D from SMC.
For more, see:
http://www.smc.eu/portal/WebContent
/main/index.jsp?lang=de&ctry=CH&is_main=yes
When does it make sense to use this equipment:
a) Compressed air escaping at the inlet to the unit «Filter regulator
positive pressure lubrication» feels moist.
b) Water droplets evident in the supply line.
c) Water separator from «Filter regulator positive pressure
lubrication» removes water effectively.

2.6.2 Pressure intensifier


Pressure intensifier, Series VBA
Pressure boosting ratio 1:2
Manually operated version (direct mounting)
Designation VBA10A-02
Pressure setting range 0.2 to 2.0 MPa
Size 1/4"
More:
http://www.smc.eu/portal/WebContent/main/index.jsp?lang=de&ctry=C
H&is_main=yes

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3 COMMISSIONING
Table of Contents
3.1 General Information ................................................................................................................................................ 25

3.2 STEP 1: Check air supply and oil pressure ................................................................................................................ 25

3.3 STEP 2: Check cabling to machine ............................................................................................................................ 25


3.3.1 Prepare automatic clamping ....................................................................................................................................... 25

3.4 STEP 3: Creating a machine backup ......................................................................................................................... 27

3.5 STEP 4: Measure and record machine geometry...................................................................................................... 28

3.6 STEP 5: Position system, provisionally align and fix in place .................................................................................... 28

3.7 STEP 6: Specify and enter the axis names and directions of rotation ....................................................................... 29
3.7.1 EA-xxx.L and EA-xxx.R ................................................................................................................................................. 29
3.7.2 T1-xxxxxx.LL ................................................................................................................................................................ 30
3.7.3 T1-xxxxxx.LR ................................................................................................................................................................ 30
3.7.4 T1-xxxxxx.RL ................................................................................................................................................................ 31
3.7.5 T1-xxxxxx.RR ............................................................................................................................................................... 32
3.7.6 Axis names and directions for profile grinding machine ............................................................................................ 32
3.7.7 Zero position: Divider in vertical position ................................................................................................................... 33
3.7.8 Kinematics of all pL LEHMANN drives ......................................................................................................................... 33

3.8 STEP 7: Enter parameters, allow axis to rotate ........................................................................................................ 34


3.8.1 Download and enter parameters................................................................................................................................ 34
3.8.2 Allow axis to rotate, check for proper clamping (each axis) ....................................................................................... 35

3.9 STEP 8: Secure the area, test the tilting axis ............................................................................................................ 36

3.10 STEP 9: Test referencing (each axis) ......................................................................................................................... 37


3.10.1 Special case, only with FANUC-PMC ........................................................................................................................... 37

3.11 STEP 10: Test of spindle clamping (each axis) .......................................................................................................... 38


3.11.1 Elementarys concerning the bleeding ........................................................................................................................ 38
3.11.2 Various pressure levels in pneumatic/hydraulic ......................................................................................................... 38
3.11.3 Bleeding of an single modul EA – procedure .............................................................................................................. 39
3.11.4 Bleeding system M - procedure .................................................................................................................................. 40
3.11.5 Bleeding system T - procedure ................................................................................................................................... 40
3.11.6 Bleeding of counter bearing on Tx- ............................................................................................................................ 41
3.11.7 Bleeding the GLA.HYD-vario - procedure .................................................................................................................... 42
3.11.8 Clamping force reduction due to counter bearing ..................................................................................................... 42

3.12 STEP 11: Recording the position of zero and the backlash, for parameterizing ........................................................ 43

3.13 STEP 12: Measure and parameterize rotation center position in X-Y-Z at 0° ............................................................ 45

3.14 STEP 13: Create a backup ........................................................................................................................................ 46

3.15 STEP 14: Run test program at 100% rapid traverse. ................................................................................................. 46
3.15.1 Recommended warm-up prior to production ............................................................................................................ 46
3.15.2 Recommended cycle for stress test (ED 20%-1min) ................................................................................................... 46

3.16 STEP 15: Check, registration, handover ................................................................................................................... 48


3.16.1 Functions test with the customer ............................................................................................................................... 48

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3.16.2 Registering the system................................................................................................................................................ 49


3.16.3 DOK-0301 « Maintenance Recommendation» and «Maintenance Journal» ............................................................. 49
3.16.4 Handover, instruction ................................................................................................................................................. 50

4 TECHNICAL INFORMATIONS ....................................................................................................... 51

4.1 Definition of the specific operating mode S3_ED20%-1min ..................................................................................... 51

4.2 Running in – CAUTION BEFORE OVERHEATING ....................................................................................................... 52

4.3 Our measuring procedure for the accuracy ............................................................................................................. 52

4.4 Technical data, motors ............................................................................................................................................ 52

4.5 Angular position measuring system (WMS) - technical data .................................................................................... 53

4.6 Technical information «blackBOX» - the rotary table electronics ............................................................................ 54


4.6.1 Meaning of LED ........................................................................................................................................................... 55
4.6.2 Features of the blackBOX............................................................................................................................................ 55

4.8 Meaning of the LED red «ERROR» ...................................................................................................................... 57

4.9 Meaning of the LED yellow «SERVICE» ............................................................................................................... 59


4.9.1 Read out the error list from blackBOX to USB stick .................................................................................................... 59
4.9.2 PNP or NPN logic ......................................................................................................................................................... 62

4.10 Zero position of the spindle as well as orientation OPT and ZUB ............................................................................. 63

4.11 Explanations of cam ring and proximity switches .................................................................................................... 64


4.11.1 Cam ring STANDARD for CNC SIEMENS, CNC HEIDENHAIN, … ................................................................................... 65
4.11.2 Cam ring for CNC FANUC ............................................................................................................................................ 66
4.11.3 Cam ring for CNC HAAS ............................................................................................................................................... 67

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3.1 General Information


The following steps describe the comprehensive commissioning of a two axis system on a machine tool.
The same steps can also be followed for single axis machines.
The work steps are described in compliance with 2006/42 / EC.

NOTE
Responsibility
The manufacturer of the «complete machine» is responsible for initial assembly and
commissioning.
 The enclosed «Assembly Instruction» according to 2006/42 / EC must be observed.
 We recommend the use of a pL LEHMANN technician or VAR.

3.2 STEP 1: Check air supply and oil pressure


See chapter 2.5 D) «Installing maintenance unit».
 Is the filter regulator-positive pressure lubrication unit
mounted at a visible and accessible location?
 Are the pressure gauges set correctly?
 Is the oil reservoirs filled approx. ⅔ full with VULCOGEAR V5?
 If the transparent oil hose filled with oil and free of bubbles?

3.3 STEP 2: Check cabling to machine


 Are the correct mating connectors mounted on the machine
and wired correctly?
 Is the plug coding correct?

3.3.1 Prepare automatic clamping


1. Is the clamping wired correctly?
2. Is the required power supply +24VDC ±10% with DC 0V available? Performance at least. 2.4W
respectively, approx. 100mA per clamping.

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NOTE
DC 0V must be connected to the same source.
The «blackBOX» electronics unit could otherwise malfunction or be destroyed!
 Check for correct wiring of the 0 V potentials.
 Check the DC 0V to earth. No voltage may be detected.
 The + +24VDC supply must NOT switch off at an EMERGENCY STOP.

3. Are the inputs/outputs required for the normal case in place?


Function Clamping unclamped Clamping clamped
Needed: +24VDC output «clamping» State = LOW State = HIGH
1x output Input «clamped» 0 1
2x inputs Input «unclamped» 1 0

4. Note 1: Control of the outputs has already been optimized with regard to timing by the
«blackBOX» rotary table electronics.
5. Note 2: The «blackBOX» permanently checks the clamping even after "clamped" or
"unclamped" is displayed.

Is the PLC programmed for the following normal case?

The normal
case:

«clamped»
AND
«unclamped»
are evaluated
by the
machine

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The special
case
No. 1:

Only
«unclamped»
can be
evaluated by
the machine

Program these times after the Program these times after the
«unclamp» signal: «clamp» signal:
507 60 ms {?? ms} 100 ms {?? ms}
The special
510 90 ms {?? ms} 170 ms {?? ms}
case
No. 2: 520 100 ms {?? ms} 180 ms {?? ms}
530 150 ms {?? ms} 330 ms {?? ms}
No inputs are
available = With time control, dwell times must be programmed.
pure time
control. The figures relate to the trigger thresholds, 50bar for "unclamped" and 120bar for
"clamped".
{?? ms} = with counter bearing
ms = milliseconds

3.4 STEP 3: Creating a machine backup


Now make a backup of all relevant software areas.

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3.5 STEP 4: Measure and record machine geometry

Measure concentricity (run-out) of


spindle.
Mark the highest point,
Note values and take into account when
aligning the pL LEHMANN system.

Measure the geometry of X, Y and


Z.
Clamp dial indicator in machine spindle for
this purpose.
The angularity of Z must be measured on
the X AND Y sides of the reference cube.
Note values and take into account when
aligning the pL LEHMANN system.

3.6 STEP 5: Position system, provisionally align and fix in place


1. Place the machine on the machine table and locate the ideal position.
NOTE: This also partly determines the names and direction of rotation of the round axes.
2. Distribute the clamping claws according to «Arrangement of the clamping claws» in «Operating
instructions STANDARD, DOK-0003», chapter 2.1, from page 16.
3. This is important with regard to the accuracy of the system. With this arrangement, the geometry
protocol was also created in the plant.
4. Now tighten the fastening screws only temporarily.
The system is then precisely aligned under STEP 11.
5. Connect the cabling.

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3.7 STEP 6: Specify and enter the axis names and directions of rotation
The following images of various pL LEHMANN systems in different positions on the machine table show
the axis names and the rotational direction of the spindles as defined in DIN 66 217.
Motor mounted on left = L = green, Motor mounted on right = R = pink
IMPORTANT: Keep in mind that the rotational direction of the spindles changes when the rotary table is
positioned on the other side of the machine table.

NOTE
We describe the rotational direction of the spindle and of the workpiece, respectively.
In programming systems, the motion of the tool is usually considered instead.
For rotary tables, it has been found beneficial to indicate the rotational direction of the spindle.

3.7.1 EA-xxx.L and EA-xxx.R

1. Left on machine table 2. Right on machine table

3. Rear and front on machine table 4. On tilting table of a B/C machine

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3.7.2 T1-xxxxxx.LL

5. Left on machine table 6. Right on machine table

7. Front on machine table 8. Rear on machine table

3.7.3 T1-xxxxxx.LR

9. Left on machine table 10. Right on machine table

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11. Front on machine table 12. Rear on machine table

3.7.4 T1-xxxxxx.RL

13. Left on machine table 14. Right on machine table

15. Rear on machine table 16. Front on machine table

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3.7.5 T1-xxxxxx.RR

17. Left on machine table 18. Right on machine table

19. Rear on machine table 20. Front on machine table

3.7.6 Axis names and directions for profile grinding machine

21. EA-L, EA-R, Links auf Maschinentisch 22. EA-L, EA-R, Rechts auf Maschinentisch

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23. T1-LL, Links, vorne, auf Maschinentisch 24. T1-RR, Rechts, hinten, auf Maschinentisch

3.7.7 Zero position: Divider in vertical position


The axis name refers to this zero position for all dividers.
The dividing / indexing axis is frequently designated the
4th axis.
The swivelling / tilting axis is then the 5th axis.

Do not adjust the cam ring:


The cam ring may not read exactly 0° at the position
«Divider in vertical position». Please do not adjust.

3.7.8 Kinematics of all pL LEHMANN drives


The worm gear has a left-hand turn.

Note the following changes, depending


on whether the motor is mounted
left/right:
a) the cam ring
b) the rotational direction of the
motor

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3.8 STEP 7: Enter parameters, allow axis to rotate


3.8.1 Download and enter parameters
Use the parameter lists at www.lehmann-rotary-tables.com
On our website you will find continuously updated parameter lists, which we provide free of charge.
Click Download/Commissioning/Parameter lists.

ATTENTION
Check selected parameter list.
Incorrect parameters can damage the system!
 We cannot guarantee the parameter lists are error-free.
 You bear the responsibility. Check the values carefully.

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3.8.2 Allow axis to rotate, check for proper clamping (each axis)

ATTENTION
Close machine doors.
Rule out the possibility of accidents before turning on the drive system and traversing for the
first times!
 Keep the axis in sight.
 Keep persons away.
 Keep the EMERGENCY STOP button within reach.

Switch on the machine and keep the EMERGENCY STOP handy.


No axis may move.
Otherwise, check parameters or cabling.
Set feed potentiometer to 0, then select an axis and enter a
manual traverse command.
Clamping must now unclamp  LED «UNCLAMPED» (yellow)
illuminates. Run for each axis.
Run forward and reverse test movements in JOG mode.

NOTE
Always clamp the spindle.
Knocks can damage the precision gear unit!
 During loading / unloading, the clamping must be «clamped».

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3.9 STEP 8: Secure the area, test the tilting axis

Slowly move the tilting axis toward the end position while
observing the LED on the motor cover. As soon as LED «END1»
or «END2» (green) illuminates, the axis must stop.
It is not possible to continue.

ATTENTION
Risk of mechanical collision! This can damage the worm gear!
Check the following points and reduce if necessary the speed!
 Are the signals of the limit switches
available? Observe LEDs on the engine cover.
 Responds the PLC correctly to these signals?
 Remember that the slowing space of the
engine at full speed can be longer (up to 30 °)
as the possible stopping distance. Of all the
systems can be affected. Particularly but the
guy OLL or ORR (engine above. See picture).
 Even large chuck or workpieces may collide
with the system. Limiting the travel if
necessary with the software limit switches.
 NOTE 1: Only T systems have hardware range
limit switch.
 NOTE 2: The hardware limit switches are not
adjustable. Do not adjust the cam ring.
 NOTE 3: At www.lehmann-rotary-tables.com Download/PLC/…Guideline… you will find PLC
examples where only the first-operated limit switch is evaluated. So you can go away at
any time. Even if both limit switches are active.
 NOTE 4: If the direction of rotation of the rotary table with parameters is changed, the limit
switch inputs END1 / END2 must be crossed out. Exception: If only one limit switch input is
evaluated by the PLC. Then can END1 and END2 be connected electronically to the black
box.
 NOTE 5: The outputs of the limit set by default as an opener. Adjustable to the black box.

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3.10 STEP 9: Test referencing (each axis)


Check for proper operation of referencing.
Set offset value. The reference point switch is not movable.

ATTENTION
The zero impuls of the motor encoder system could arrive in the same moment as the signal
of the reference point sensor.
In this case the reference point can float about 1 motor rotation, depending whitch signal will
arrive earlier.
 Run the reference point several times and check the ever same and correct zero position.
 If necessary, move the came ring on the spindel of the rotary table a little, maximum the
half of the way of a motor turn. More instructions see chapter 5.2.1 «Zero position of the
spindle».

3.10.1 Special case, only with FANUC-PMC

NOTE
FANUC Standard PMCs do not know detect changes of direction during referencing.
If you start in the wrong position, you move to the limit switch.
For this reason, the system MUST be started from a certain position (area)!
 When referencing, two signals MUST be received from the reference point switch. These
are «cam reached» and «cam exited». The next zero pulse from the motor encoder is then
accepted.

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3.11 STEP 10: Test of spindle clamping (each axis)


Proper operation of clamping was ensured above.
CAUTION: CNC or PLC/SPS controls do not always correctly manage the «Positioning rotary axis WITH
CLAMPING» process.
The following malfunction has been observed several times and has very bad impact :
The control system deletes the lag error simultaneously with shutting down motor control. The result is
slow and unnoticed shifting of the zero point – and workpiece!
CORRECT IS:
The motor must control the axis all the way to its target position and hold there until the clamping has
full clamped. The lag error memory must never be deleted.

ATTENTION
The momory of positioning monitoring could be deleted.
That can slowly move the zero position.
 The motor must hold the axis until the clamping system has full clamped.
 The lag-error-memory shall NEVER be deleted.

3.11.1 Elementarys concerning the bleeding


Clamping and gear units are sealed against all but the smallest
oil leak. These smallest leaks are continuously compensated by
the maintenance unit (see chapter 2.5).
All components are careful bleeded before shipping. Inclusive
the oil hose and flow-blocked couplings.
Ensure that NO air gets into the oil hose during installation. Even
small air bubbles cause the clamping to slow down.
If there is too much air in the system, the clamping goes in error
status.

3.11.2 Various pressure levels in pneumatic/hydraulic


Air pressure for BRAKY clamping: 5…6bar
Oil pressure for oil leaks: 0.3…0.5bar
Oil pressure of clamping, Modul 507: 150bar
Module 5x0: 220bar
More informationes see schemas pneumatik-/hydraulic,
chapter 7.

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3.11.3 Bleeding of an single modul EA – procedure

HINWEIS
The clamping must be unclamping for bleeding.
Otherwise the oil cannot flow!
 Observe LED on the motor cover.

1. If necessary, refill the maintenance unit with the special oil


VULCOGEAR V5. Readjust the compressed air on the pressure
gauge to the specified value.
2. Bleed openings «C» (clamping) and «G» (gear) must be in
position "face up".
3. The clamping must be «unclamped». (LED yellow «UNCLAMPED»
is lightening).
4. Bleeding the gear unit: Remove screw «G» (6) on top of module
with (5), leave ball (7) inside. Wait until bubble-free oil flows out,
then close.
5. Bleeding BRAKY and clamping system: Remove screw «C» (6), leave ball (7) inside. Wait until bubble
free oil flows out, close.
6. ONLY IF NECESSARY - Bleeding through pulsation: Remove
screw «C», leave ball inside. Then actuate clamping several
times. Either electronically or with the blue button on the valve
(see picture on this page). The larger the oil stream at «C»
when clamping, the better the system is bled. Close again.
NOTE:
a) When clamping with the open bleed hole «C», the piston
of the BRAKY goes to the end position on bottom.
b) When unclamping, the ball prevents, that air is drawn in
the oil system. That results a vacuum for a harmless short
time, just at the piston does no more close the
compensation hole for oil (until the last few mm).
c) Observe the ball. It can jump out and be lost.
7. Check oil level in the maintenance unit, repfill if necessary.
8. OPTIONAL: Check clamping pressure with a pressure gauge. See
ACA documentation.

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NOTE
Pulsating bleeding works faster.
Clamp/unclamp conveys air bubbles along!
 Observe LED on the motor cover.
 Do not increase the oil pressure on maintenance unit for bleeding. Seals can be pushed
out or destroyed.

3.11.4 Bleeding system M - procedure


Same procedure as single module EA.
Start with the module close to motor.

3.11.5 Bleeding system T - procedure


Similar procedure as sytems EA and M.
The oil circuit of tilting module and counter bearing are connected to BRAKY tilting module: Remove
screw «C» on top of counter bearing. Wait until oil wells without air. Close again.
Bleeding the tilting module: Move the clamping several times.
Bleeding the counter bearing: Move the clamping several times.

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3.11.6 Bleeding of counter bearing on Tx-

NOTE
Get to know the vave funktion!
Misinterpretations are easily possible!
 See the following pictures.

Through the base plate


In the case of systems with a counter bearing and base plate, the oil pressure line runs through the base plate.

All housings are prepared in Milled partial surface for venting: EA rotary table (single modul):
this way: The plug GK.42 has a surface that (1)' Closed against contamination.
(1)' Pessure of oil 220bar. allows air to escape rapidly during (2)' Closed against contamination.
(2)' Locking plug GK.42. venting. Therefore, it must also be (3)' Closed against 220bar.
(4)' Threaded hole as parking for at the top during the venting
GK.41 if not used.. process.

T-system with counter bearing: Separate the counter bearings again: (This is the advantage!)
(1)' it open. The counter bearing can be separated without disassembling the
(2)' Closed now against 220bar. system. Simply insert GK.41, done.
(4)' GK.41 is parked.

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3.11.7 Bleeding the GLA.HYD-vario - procedure


1. Remove the screw «C» on top of the GLA,
wait until bubble-free oil flows, then close.
2. Bleeding tilter clamping: Actuate clamping
several times.
3. Bleeding counter bearing clamping:
Actuate clamp several times.

3.11.8 Clamping force reduction due to counter bearing


Maximum length: Measuring tube 1.5m, steel tube 2m, otherwise contact the supplier.
The elasticity of the flex or steel tube loads the stroke reserve of the pressure unit BRAKY.
Very good venting is therefore important! Particularly important for systems 507 and 520.
When the piston stroke is fully utilized, the clamping force on the counter bearing and the rotary table is
reduced as well!

NOTE
Clamping force reduction with GLA.HYD-vario.
For EA-520 with 520 counter bearing and flexible hose!
 The reduction is approx. 10%.
 Applies equally to module and counter bearing.
 Careful bleeding pays off.
 Use WZP.BRAKY.KTR 5.0 control system.

ATTENTION

Never clamp without bearing pin.


Doing so will destroy the clamping ring immediately!

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3.12 STEP 11: Recording the position of zero and the backlash, for parameterizing
IMPORTANT: First align the system according to the «operating instructions DOK-0003»
chapter 3.

In the following, instead of the measuring mandrel, pL


no. RIP.63.KD-1, a chuck or a flange with a surface can
also be used.

1. Reversal (backlash) of tilting axis at 0° 2. Reversal (backlash) of dividing axis


a) Move from -90° auf 0° (vertical position) (1) Measure in the same way, parameterize
b) Measure the position
c) Drive to +5°, the drive to 0° (2)
d) Measure the position
e) Parameterize the difference as backlash
f) Repeat, check
NOTE: The control distance must not be too short.

3. Ref. point correction (zero pos) tilting axis 4. Ref. point correction (zero pos) of dividing
a) Straighten the measuring mandrel vertically axis
b) Remember position on CNC
c) Move the reference point Do it in the same way as by the tilting axis.
d) Parameterize the position difference
e) Repeat, check

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5. Parameterize slope error1 (OPTIONAL) 6. Complete the «Geometry acceptance


a) Drive to -90 ° report»
b) Measure position errors
c) Enter linear errors in the rising error table In the case of an intervention by the «Technical
(parameterize) Service», all tolerances for aligning the system are to
d) Check at 0 ° and -90 ° be taken from the «Abnahmeprotokoll Geometrie /
1 = «Rising error», also referred to as «pitch error» or Geometry acceptance report» (DOK-0214).
«spindle slope correction». Also the final measurements shall be carried out and
Corresponds to the pitch error per length of a ball documented in accordance with instructions in this
screw. Comparable with value 11 and auxiliary mass 1 document.
of «Test protocol geometry / Geometry test report».

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3.13 STEP 12: Measure and parameterize rotation center position in X-Y-Z at 0°
These steps are only necessary if a complete kinematic definition is created. This must be known:
 Mechanical position of the zero point in X / Y
 Distance from machine to spindle surface of the divider (Z axis).
 Top height (center of rotation) of the swivel axis
 Offset between the two axes of rotation

1. The center of the dividing axis is the


machine tool zero point
a) Set to 0° (zero point) the tilting axis
b) Measure the position
c) Set this coordinates in the CNC as machine tool zero
point C in X-Y

2. Offset 1 and center hight tilting axis


a) Take values from Geo-protocol and set them in the
CNC

Center height of tilting axis -> value 4


Offset 1 -> auxiliary value 2

Spitzenhöhe = center hight

2. Offset 2
b) Take values from Geo-protocol and set them in the
CNC

Offset 2 -> auxiliary value 4

Schwenkachse = tilting axis

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3.14 STEP 13: Create a backup


Now run the backup. Then, in the case of disturbances, the rotary table
parameters are also retained.
The same also applies after service work on the system.
The data backup remains in your own responsibility.

3.15 STEP 14: Run test program at 100% rapid traverse.


3.15.1 Recommended warm-up prior to production
First cycle:
Indexing axes: Feed 20% of max. speed: 10x (+360° / pause 5 sec. / -360° / pause 5 sec.)
Tilting axes: Feed 20% of max. speed: 20x (limit plus° / pause 5 sec. / limit minus° / pause 5 sec.)
Second cycle:
Dividing / indexing axes: Feed 50% of max. speed: 20x (+90° / pause 2 sec. / -90° / pause 2 sec.)
Tilting axes: Feed 50% of max. speed: 10x (limit plus° / pause 5 sec. / limit minus° / pause 5 sec.)

3.15.2 Recommended cycle for stress test (ED 20%-1min)


Only permitted after warm-up.
Maximum spindle load per «Standard spindle load» in the pL
LEHMANN main catalog.
Clamp spindle clamping after each positioning.
Cycle for rotary axis:
Feed 100%: 10x (+180° / pause 4x the time for run 180° (see main
catalog), then repeat at -180°).
Cycle for tilting axis:
Feed 100%: 20x (0° / pause 4x the time for run 180° (see catalog
pL), then -90°).

The rotary table electronics blackBOX checks the duty cycle and enters
«Error 022» in the logbook if the time is exceeded.

ATTENTION
Continuous turning can cause serious demages.
Heat accumulation in the gear box can destroi it.
The motor becomes can overheat
 Maintain a duty cycle of 20%-1min.

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 Read the instructions in this regard.

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3.16 STEP 15: Check, registration, handover


3.16.1 Functions test with the customer
 Traverse by hand.
 Execute referencing.
 Run to hardware limit switch.
 Run to software limit switch.
 Activate EMERGENCY STOP.
 Rotate ±90°, check.
 Check «ERROR» generation by the blackBOX, e.g., by shutting
off the compressed air.

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3.16.2 Registering the system


Register the system at www.lehmann-rotary-tables.com under Service/Product registration

3.16.3 DOK-0301 « Maintenance Recommendation» and «Maintenance Journal»


The following document is enclosed by the package insert by all deliverys of new rotary tables.

DOK-0301 always put into the dossier «Machine maintenance»!


All maintenance on the rotary table must be entered in the maintenance journal.

 It must be always abailable to the maintenance technicians


 It must be always sent for external maintenace work.
 Note for the executing engineer: If the document is missing, executed maintenance are to be en-
tered in the text document DOK-0301 on the USB stick.

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3.16.4 Handover, instruction


Handover the functional system to the responsible person.
Explain at least the following points.
 Range of motion
 Area safeguarding HW/SW
 Reference point, shifting
 Parameterized maximum values for speed and torque, etc. at
standard load. Refer to operating manual STANDARD DOK-
0003.
 Meaning of S3 ED20%-1min
 EMERGENCY STOP
 blackBOX error messages
 Check oil level. Special oil obligation.
 Maintenance journal belongs to maintenance documents

NOTE
Operating manual STANDARD.
The document DOK-0003 must be printed and available at the machine!
 It contains important information about the load on the system.
 The use of accessories is also described in this document.

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4 Technical informations
4.1 Definition of the specific operating mode S3_ED20%-1min
All drive data refer to the operating mode «Intermittent operation S3_ED20%-1 minute» in accordance
to VDE0520 with loaded spindle with STANDARD load, according to the operating instructions
STANDARD, DOK-0003, chapter 5.

THE KEY MESSAGE OF THE DIAGRAMS IN WORDS: During the viewing period of 60 sec, a maximum
work time of 12 sec by max speed and STANDARD load is allowed.

ATTENTION
MAXIMUM RUN TIME 12 SECONDES – NO PERMANENT OPERATION ALLOWED
Otherwise, the worm gear can be destroyed by overheating!
Run the rotary table for max 12 sec at max speed, especially when the module is cold.
Otherwise, the gear can be destroyed by different material extensions.

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4.2 Running in – CAUTION BEFORE OVERHEATING


If necessary, it must be ensured that a long waiting period is programmed.
Also at tilting axis it must be ensured that a long waiting period is programmed. S3_ED20%_1min also
applies here.

ATTENTION
MAXIMUM RUN TIME 12 SECONDES – NO PERMANENT OPERATION ALLOWED
Otherwise, the worm gear can be destroyed by overheating!
Run the rotary table for max 12 sec at max speed, especially when the module is cold.
Otherwise, the gear can be destroyed by different material extensions.

4.3 Our measuring procedure for the accuracy


We carefully measure and record all rotary table modules after finishing.
As measuring equipment serve a HEIDENHAIN ROD 800 with coupling K 15.
The measuring procedure is based on VDI/DGQ 3441 or ISO 230-2.
Measured after the rotary table has warmed up as follow:
Warm up: 5 cycles with 24 steps to +15° and 24 steps to -15° with 3 sec break between steps.
Procedure for subsequent measuring: 5 cycles with 24 measuring points spaced 15° apart. With these
data:
o Acceleration 500°/s2
o Feedrate 1000°/min
o Ambient temperature approx. 22°
o Unloaded spindle
Applies only to indexing axes. Without toothed belt drive system.

4.4 Technical data, motors


Please download from our website.

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4.5 Angular position measuring system (WMS) - technical data

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4.6 Technical information «blackBOX» - the rotary table electronics


The electronics unit controls and monitors the system. It is
located below the motor cover.

Voltage: + 24V / 0V
Current: 0.1A max Standard 0.3A max with servo valve
1 input: "clamp", optionally + 24VDC ca.5mA
or 110VAC ca.25mA without hardware
measures.
For AC control, the «Input Clamp» software parameter must be set to «AC».
Otherwise, the pneumatic valve rattles.
8 outputs: Ready, Error, Unclamped, Clamped, Reference, Limit1, Limit2, Service.
Current: Each output individually max.50mA
NPN / PNP: Can be rewired collectively.
Buffer: The data is battery-buffered.
Software: On delivery, the current operating system and, due to the notified location, the
appropriate machine parameters are loaded.
Interface: USB interface, accessible from the outside.
Installation: All connections are plugged in, the print is inserted on a holding plate.
Connector J17: Pin 1+3 = Input «clamp», universal. The input electronic ist able for voltages from 24 V
to 130 V DC or AC.
IMPORTANT: The zero volt of AC resp the neutre shall never connected to zero volt
resp masse/earth of 24V DC. Even when they are connected on machine side! This can
cause difficult malfunctions.
DO NOT FORGET: When the signal «clamp» is AC, the parameter «Input terminal»
must be set to «AC» on the blackBOX. Otherwise the pneumatic valve rattles.
The previous input «clamp» on connector J5 pin 1 + 3 (version I) is further present, but
is no longer mentioned on the schematic.
Plug J18: Since about 11/2016 we always equip J18 with a resistor of 4700 Ohm. This serves for
the artificial loading of the output on the machine tool. This is often necessary for the
monitoring of the machine to work.
At 110V, the resistor is under the
motor cover screwed onto the
retaining plate in order to dissipate
the heat.
LED lamps: 12 LEDs in 4 colors on the motor
cover signal the operating condition

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4.6.1 Meaning of LED

LED Color Function Comment


SPEED yellow Worm speed Flashes 1x per worm revolution
Extinguishes when end position «-» is reached (only for tilting
END2 green Limit switch 2 (-) UZ
axes with connected limit switches.)
Extinguishes when end position «+» is reached (only for
END1 green Limit switch 1 (+) GUZ
tilting axes with connected limit switches.)
REF yellow Ref. Spindle Illuminates/extinguishes on the edge of the cam / slot
 Flashes in idle state at 2 second intervals if OK.
 Flickers during read in/out on USB stick or EPROM.
RW/CPU green EPROM / USB stick
 Illuminates permanently/does not illuminate if system is
not ready
SERVICE yellow Service Flashing sequence. For code key, see below.
CLAMPED green Spindle clamping «clamped» Illuminates when spindle clamping is clamped
UNCLAMPED yellow Spindle clamping «unclamped» Illuminates when spindle clamp is unclamped
CLAMP blue «clamp» spindle clamping Illuminates when signal for clamping is present
Illuminates permanently when system is ready. NOTE: If error
READY green System OK. messages are displayed and the LED «READY» is nevertheless
illuminated, only warnings are involved.
ERROR red Error Flashing sequence. For code key, see below.
+24VDC green Power System OK. Illuminated continuously when the power supply is OK.

4.6.2 Features of the blackBOX

No. Function I/O LED Type

1 Measuring of temperature and humidity below the motor cover. Standard

Controls spindle clamping. Digital «clamp» input. May be inverted


2 CLAMP blue Standard
by means of «blackBOXcom.exe» software or DIP switch.

Monitors spindle clamping. Digital «clamped» and «unclamped»


CLAMPED green
3 outputs. Setting as NOC/NCC by means of «blackBOXcom.exe» Standard
UNCLAMPED yellow
software, setting of PNP-/NPN logic by means of cabling.

1) Measure the speed of the worm gear and yel-


4 SPEED Standard
2) Count the worm gear rotations (switching magnet). low

5 Monitors the sealing air in the motor cover. Standard

Continuous evaluation of the sensors for acceleration in the X- and


6 Standard
Y-direction to identify shocks, impact, crashes.

7 Output of existing errors. ERROR red Standard

8 Output of «Ready» signal. READY green Standard

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No. Function I/O LED Type

Evaluation and output of the reference signal. The output signal is


adjustable. Adjustable in terms of NOC/NCC by means of «black-
9 REF yellow Standard
BOXcom.exe» software, in term of PNP-/NPN logic by means of ca-
bling.

Evaluation and output of the range switch plus/minus.


The signals are not adjustable. Adjustable in terms of NOC/NCC by END1 green
10 Standard
means of «blackBOXcom.exe» software, in term of PNP-/NPN logic END2 green
by means of cabling.

11 Output of maintenance information. SERVICE yellow Standard

12 Rotary table licensing via USB stick. Standard

13 Realtime clock for the registration of data with time and date. Standard

Backup battery for the realtime clock with monitoring.


14 Standard
Service life, 5 years.

15 Memory for recording process data (approx. 5000 history entries). Standard

16 Monitors the supply voltage. +24VDC green

17 Remote control of a pressure intensifier. e.g. for counter bearing. Option

18 Measure current with external sensor for current. Option

PC software for parameterization and visualization of history and


19 RW/CPU green Option
ACTUAL values.

20 Monitors the pneumatic pressure (e.g. 6 [bar]). Option

21 Controls sealing air pressure via proportional valve. Option

Web server function by means of additional PCB with


22 Option
USB/Ethernet adapter.

NOTE
Often faults on the blackBOX.
 Don't connect 0V_AC with 0V_DC.
 If the clamping signal is in AC, you must adjust on blackBOX the parameter DC  AC
 Ever connect the cable shield on machine side to earth.

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4.8 Meaning of the LED red «ERROR»


In the event of a fault, the red «ERROR» LED flashes
continuously.
When there are several errors, the flashing code for
the next error follows after a pause of 3 seconds, and
so on. The errors do not appear according to their
importance, but in ascending order.
For some errors, the rotary table can continue to
work; in others the signal «READY» goes to 0V and
requires the rotary table to be switched off. See table.
Action: Call technician for machine maintenance.
Example for LED red «ERROR»: Blink code series for «Rel. Humidity (2) AND «Vacuum housing» (4)

Table of flashing codes of the LED red «ERROR»


If flashing, call immediately maintenance technicians.

Switching
Blinkzahl

threshold Signal
Flashes/

Meaning Short explication (ex.)/Schalt «READY»

E/B(1)
Opt.
Bedeutung Kurzerklärung schw.(Bsp) (2)
Temperature Level Internal temperature exceeded
1 E 85 [C°] 0
Temperaturniveau Temperatur Intern überschritten
Humidity Level Relative humidity exceeded
2 E 50 [%] 0
Relative Luftfeuchte Relative Luftfeuchte überschritten
Box Overpressure Housing overpressure exceeded
3 E 500 [mbar] 0
Überdruck Gehäuse Überdruck Gehäuse überschritten
Box Underpressure Below min. pressure for motor add-on /
4 B 100 [mbar] 0
Unterdruck Gehäuse Mindestdruck Motoranbau unterschritten
Box Overcurrent Overcurrent at proportional valve
5 E x 0.100 [A] 1
Überstrom Prop-.-ventil Überstrom am Proportionalventil
Box Undercurrent Undercurrent at proportional valve /
6 B x 0.001 [A] 1
Unterstrom Prop.-ventil Unterstrom am Proportionalventil
System Overpressure Air pressure too high
7 E x 7.0 [bar] 0
Luftdruck zu hoch Luftdruck zu hoch
System Underpressure Air pressure too low
8 B x 4.0 [bar] 0
Luftdruck zu tief Luftdruck zu tief
Motor Overcurrent Overcurrent at motor
9 E x (10 [A]) 1
Überstrom am Motor Überstrom am Motor
Impact Max. X Impact / acceleration X exceeded 10 [g] 30
10 E 1
Max. Schlag X Schlag / Beschleunigung X überschritten [ms]
Impact Max. Y Impact/acceleration Y exceeded 10 [g] 30
11 E 1
Max. Schlag Y Schlag/Beschleunigung Y überschritten [ms]
12 Spindle Clamp Timeout «Clamp» time exceeded E 2 000 [ms] 1

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Switching
Blinkzahl

threshold Signal
Flashes/

Meaning Short explication (ex.)/Schalt «READY»

E/B(1)
Opt.
Bedeutung Kurzerklärung schw.(Bsp) (2)
Zeit «geklemmt» überschritten Zeit «Klemmen» überschritten
Spindle Release Timeout «Unclamp» time exceeded
13 E 2 000 [ms] 1
Zeit «gelöst» überschritten Zeit «Lösen» überschritten
Valve Spindle Clamp Current Overcurrent at clamping valve (short
14 Standby / Überstrom am circuit?) E 10 [mA] 0
Klemmungsventil Überstrom bei Klemmventil (Kurschluss?)
Valve Spindle Clamp Current Current too low at clamping valve
15 Operation / Unterstrom am (broken wire?) B 1 [mA] 0
Klemmungsventil Strom zu tief bei Klemmventil (Kabelbruch?)
External pressure intensifier Error external pressure intensifier
16 1
Externer Druckübersetzer Fehler externer Druckübersetzer
License Expired License expired
17 0
Lizenz abgelaufen Lizenz abgelaufen
License Key Invalid License key incorrect
18 1
Lizenzschlüssel falsch Lizenzschlüssel falsch
System time (RTC) System time wrong
19 0
Systemzeit falsch Systemzeit falsch
Max. Revolution Speed Max. rpm exceeded (11 000
20 E
Max. Drehzahl überschritten Max. Drehzahl überschritten [rpm])
Accelerator IRQ Interruption request
21
Unterbruchsanforderung Unterbrechungsanforderung
Revolution On Time Max. On-time for motor duty cycle (ED)
22 E
Max. ED überschritten exceeded / ED Motor überschritten
Init. Operat.; No Module number No serial number parameterized
25 0
Keine Serie-Nr. parametriert Keine Serienummer parametriert
Init. Operation; Clamp Pressure Sensor initialization for clamping
26 Calib. / Initialis. Klemm.-sensor calibration not correct / Initialis. Sensor 0
unvollst. für Klemmung - Kalibrierung nicht richtig

Init. Operation; System Pressure Sensor initializ. for operation pressure


27 Calib. / Initialis. Sensor calibration not correct (e.g. 6 bar) / 0
Initialisierung Sensor für Betriebsdruck -
Betriebsdruck unvollständig
Kalibrierung nicht richtig (z.B. 6bar)
Init. Operation; Box Pressure Sensor initialization for sealing air
28 Calib. / Initialis. Sensoren calibration not correct / Initialis. Sensor für 0
Sperrluft falsch Sperrluft - Kalibrierung nicht richtig
Init. Operation; Accelerator Sensor initialization for acceleration
29 Calib. / Initialis. Sensoren calibration not correct / Initialis. Senso. 0
Beschleunigung falsch für Beschleunig. - Kalibrierung nicht richtig
(1)
E = Exceed, B = Below
(2)
«READY» = Signal high = i.O, low = Fehler/Error

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4.9 Meaning of the LED yellow «SERVICE»


If necessary for "SERVICE", the corresponding code
flashes continuously.
For further instructions see "Maintenance
Recommendation" and "Maintenance Journal" DOK-
0301 which was included with the package insert. It is
also stored on the USB stick of the pL rotary table.
The always tracked document must be stored during
machine maintenance.

Example of «SERVICE» LED yellow: Flashing code for «revolutions of the worm» («rev. of worm»)

Table of flashing codes of the yellow LED «SERVICE»


If flashing, refer to the instructions in document DOK-0301 "Maintenance Recommendation" and "Maintenance
Journal".

Number of
flashes /
Blinkzahl Meaning / Bedeutung Short explication / Erklärung

Clamping cycles Set number of «clamp cycles» exceeded.


1
Klemmzyklen 1 clamping cycle is made of «unclamp+clamp» and the signal control.

Rotary table «ON» Set number of «operating hours» exceeded


2
Drehtisch «EIN» The counter starts when the blackBOX is "on".

Worm is turning Set number of «partial operation» hours exceeded.


3
Schnecke dreht Der Zähler läuft, sobald die Klemmung gelöst ist.

Rev. of worm Set number of «worm revolutions» exceeded.


4
Umdr. Schnecke Sensor at the belt pulley.

4.9.1 Read out the error list from blackBOX to USB stick
The blackBOX records all errors in a history file. This history file can
be exported via the USB interface (Type USB-A).

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The USB connectors are located next to the flexible tubing


outlet.

For reasons of accessibility on the rotary table, only short USB sticks can
be used.
On delivery, one USB stick with the system data is inserted in this
connector port. For more information in this regard see chapter 1.

NOTE
USB stick with a maximum of 8GB possible.
Risk of addressing errors on larger USB sticks!
This limitation is due to the software in the blackBOX.

Procedure:
1. Prepare USB stick for data backup by creating a
«Param» folder at the highest level.

2. Unscrew the protective cap on the USB connector


on the motor cover.

3. Insert USB stick.

4. LED green «RW/CPU» flickers briefly, the data are


transferred in 5 seconds at the most.

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5. Remove USB stick.

6. Replace protective cap on the rotary table and close


tightly.

Evaluating the error history:


7. There should now be a file
«param_[Modulnummer].txt» in the «Param» folder.

8. Open file with text editor (e.g. WordPad).

9. Line number 0 indicates the most recent event. (Check:


Time).

10. When an error appears, its 3-digit number is displayed


(004).

11. If an error disappears again, the first digit of the error


number is replaced with a 1 (104).

Read example for lines 5 and 4:


5 = 004; 2011-01-13 09:55:05; 0
Error 4 occurs on 13.01.2011 at 09:55:05

4 = 104; 2011-01-13 12:17:05; 0


Error 4 disappears on 13.01.2011 at 12:17:05

Preparing the error messages


Please record the error messages for your discussion with the service
technician.

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4.9.2 PNP or NPN logic


Both PNP and NPN circuits are possible.
Default setting is PNP.

Difference in input for clamping:


PNP = inflowing current (+V) activates the input.
NPN = outflowing current (0V) activates the input.

Difference at outputs e.g. reference point:


PNP = When the output is active, current flows outwards
(against 0V)
NPN = When the output is active, current flows inwards (from
+ V)
Standard wiring is PNP.

Mixed connection
The «clamping» input and the 8 outputs are independent
groups. They can be configured differently in terms of PNP/NPN
logic.

Changing from PNP to NPN is strictly a mater of wiring.

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4.10 Zero position of the spindle as well as orientation OPT and ZUB
The initial position «0°» is taken when mounting a rotary table modul, as well for mounting options and acces-
sories. Not to be confused with the reference point an the limit switches. The cam ring can be rotated on the
spindle.

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4.11 Explanations of cam ring and proximity switches


All 3 proximity switches are installed in a common mount.

Due to the configuration, the reference point for size 520 is at


approx. 16°.

In the figure: Version for motor mounted at left, 90° range of


motion.

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4.11.1 Cam ring STANDARD for CNC SIEMENS, CNC HEIDENHAIN, …

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4.11.2 Cam ring for CNC FANUC

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4.11.3 Cam ring for CNC HAAS

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5 Troubleshooting
5.1 Malfunction table

No Malfunction Cause Measure Who(*)


Gear unit friction too high or gear Gear unit damaged from collision
1. Repair by VAR. (1) PASE
unit jamming. or moving with clamped spindle.
Motor quickly in overcurrent, wrong PTME
2. Cam ring blocked. See images below.
reference point. (@EA)
Oil pressure in maintenance unit at
a. Oil pressure too high. PTME
0.3 ... Set to 0.5 bar.
3. Oil loss on spindle or worm gear.
Seal defective, clamping ring not
b. Repair by VAR. PASE
tight.
a. Air supply interrupted. Set to 6 bar on maintenance unit. PTME
b. No clamping signal. Check signal source and path. PTSE
c. Maintenance unit is empty. Refill oil, bleed system. PTME
4. Spindle clamping does not clamp. Oil pressure regulator is set to 0 Oil pressure in maintenance unit at
d. PTME
bar. 0.3 ... Set to 0.5 bar.
e. Kink in oil hose. Eliminate. PTME
f. Air in hydraulic system. Bleed. PTME
5. Spindle clamping does not release. Disturbances on blackBOX cable. Check connection of shields. PTSE
Rotary table not connected Check plug on interface to the
a. PTSE
6. Workpiece spindle does not rotate. correctly. machine.
b. Malfunction in CNC control. Evaluate error messages. PTSE
7. Gear unit stuck. Maintenance unit is empty. Repair by VAR. PASE
Rotary table runs slightly too far PTME
8. Toothed belt damaged. Repair by VAR.
when moving approximately > 60°. (@EA)
U-V-W phases connected
9. Motor does not rotate. Correct. PTSE
incorrectly.
a. Gear backlash. Program backlash compensation. PTSE
Position approached
10. b. WMS mounted by VAR. PTSE
forward/backward has deviation.
c. Transmission ratio incorrect Repair by VAR. PTME
a. Loose cam washer. Tighten screws PTME
Reference point not found or
11. The signal edge of ref and zero Rotate cam ring on spindle approx
sometimes offset. b. PTME
pulse of encoder are too close. 1-2mm.
a. BRAKY error PTME
«clamped» signal released after
12. Hydraulic fitting at base plate Remove system from machine
about 20 sec. b. PTME
leaking. table. Tighten fittings.
«clamp» and «unclamped» signal Earthing connection not clean.
13. Consult VAR. PASE
sometimes flicker. Shield not connected.
The motor rotates but the spindle
14. Motor shaft broken. Repair by VAR. PTME
does not move.
Clamping unclamped increasingly Air outlet at the bottom of the
15. Clean. PTME
slowly. housing is clogged.
«clamped» signal sometimes fails to
16. Air in system. Bleed. PTME
appear.
«clamped» signal sometimes Air pressure briefly drops below
17. Repair hall air supply line. PTME
disappears briefly and then returns. the limit value.
(1)= VAR = Ihr Landesvertreter. Siehe www.lehmann-rotary-tables.com/de/Kontakt/vertretungen/
(*) = PTME = pL trained maintenance engineer for Enduser
PTSE = pL trained service engineer for OEM
PASE = pL authorized service engineer (freelancer from VAR)
PCSE = pL certified service engineer

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5.2 Cleaning the cam ring


Very fine chips can clog the cam ring despite the sealing air pressure. That can cause the motor to
overheat or incorrect referencing.

Attach a mark, remove cam ring. a. Pull cam ring, clean. a. Place 4 shims 0.05mm under-
507: s=2.5mm (M5 in front) b. Clean also behind the ring. neath, slide on the cam ring,
510: s=1.5mm (M3) b. adjust the mark,
520;530: s= 2mm (M4) c. tighten the screws (3) with:
510 = 0,6Nm
507, 520, 530 = 1,2Nm
c. Remove shims.

Never use the ball head hew


wrench!

5.3 Retrofitting SPI.Lab


In case of heavy sludge or abrasive substances, it may be
advisable to retrofit the SPI.5xx-Lab option. Possible only at
VAR or in the factory.
The option SPI.Lab consists of a non-contact labyrinth seal at
the front of the spindle through which a constant stream of
compressed air flows.

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WALL PENETRATIONS WDF

6 Description of the wall penetrations «WDF»


6.1 Overview on pL LEHMANN STANDARD cabling

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WALL PENETRATIONS WDF

6.2 Please CONSIDER when placing the mating connector on the machine

 Place mating connector as high as possible to protect it from


water and metal chips.
The mating plugs should be readily accessible.

 Keep motions of the flexible tubing in mind at MAXIMUM


TABLE MOTIONS. The bending radius must not be less than
100 mm even at the extreme positions.

 The flexible tubing must never be pinched, twisted or kinked.


 It must be protected from hot metal chips and abrasion.

 Wire / hose routing after the wall penetration:


 Route cables and hoses in a way that protects them against
kinking, pinching, abrasion, excessive heat, etc.
 If possible, the oil hose should remain visible over its entire
length up to the maintenance unit.
 This is the only way to ensure that no air bubbles remain in
the oil when bleeding.

WARNING
Electric shock from high motor voltage.
Danger of serious injury!
 Always consult the regulations of the relevant technical personnel for installation.

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WALL PENETRATIONS WDF

6.3 Description of wall penetration WDF with connectors «K8»


All necessary parts are supplied loose in the same package. Including 4 screws for attaching the
aluminum housing. Without crimping tool. The contacts can also be soldered. An extraction tool is
included.
For connector assignment, see diagrams in the chapter «Diagrams WDF».

6.3.1 Couplings for air and oil () X2PS1x


Place the coupling for oil (0.3-0.5 bar) at position C of the HARTING
insert. The coupling shuts off drip-free.

Place the coupling for compressed air (5-6 bar) at position B.

Connector assignment for air and oil couplings on connector X2PS1x

Location No. Function Element Name


a not used
b 1 Compressed air 5-6 bar 6/4 BU T2DU1x
2 IP68 (Option) 6/4 BK T2SS1x
3 Not used
c 1 Pressurized oil 0.3-0.5 bar 6/4 WH T2PS1x

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WALL PENETRATIONS WDF

6.3.2 Wall penetration WDF for the enclosure wall «K8»


The watertight aluminum connector box is fitted with the
HARTING mating connectors, size 10B/EMV (IP67), with metal
latches (incl. aluminum protective caps).
The rear side of the connector box is closed by a screwed-on
cover.

Depending on the motor or servo, the cable ends on the machine side
already have connectors attached.
For connector assignment, see the diagram at «Diagrams WDF».

Cable length 10 m, the first 5 m in flexible tubing with M32x1.5 end


fitting.

Hose length for air and oil also 10 m, the first 5 m in suitable flexible
tubing with non-leaking cable gland.

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WALL PENETRATIONS WDF

6.3.3 Coding of cable connectors and device couplings «K8»


Single axes (EA-5xx) are always coded as «1st rotary axis».
The dividing / indexing axis on T-systems (Tx-5xx5xx, 360° motion) is always coded as «1st rotary axis».
The swivelling / tilting axis on T-systems (Tx-5xx5xx, limited range of motion) is always coded as «2nd
rotary axis».

X2M1x HanK8/24 (motor, 24 V sig.) and


X2A1x Han42DD (encoder + WMS)
X2PS1x (oil and air)

1st rotary axis

(divider)

Code
type I Code type II

2nd rotary axis

(swiveller / tilter)

Coder Code type IV


type III

Red = Coding socket (item no. 120-2002) Blue = Coding pin (item no. 120-2001)

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WALL PENETRATIONS WDF

6.3.4 WDF. … -S … – Drilling template for control cabinet wall penetration «K8» & «R1»
With the WDF you receive this template printed on adhesive film.

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WALL PENETRATIONS WDF

6.3.5 WDF. … K – Drilling template for enclosure wall penetration «K8»


Print the template if necessary.

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WALL PENETRATIONS WDF

6.4 Description of wall penetration WDF with connectors «MIL»


6.4.1 WDF.R1 – mating connector for round connector «MIL» (b a)
We supply the basic device couplings as shown, with screw-on covers.
For contact assignment, see diagrams.
NOTE: The assembly «WDF.lo – Wall penetration for air/oil» is part of
WDF.R1 and it thus provided automatically. For more information on
WDF.lo, see further below.

WDF.R1 – bill of materials


pc No Name Order designation Code.
1 120-0876 Flange socket MS3102A 28-11S N-code
1 120-1824a Flange socket MS3102A 20-29SW W-code
1 120-0943 Cover size 28 Metal With chain.
1 120-0943d Cover size 20 Metal With chain. 28-11SN-WDF 20-29SW-WDF

WDF.R1z – bill of materials


pc No Name Order designation Code.
1 120-0876a Flange socket MS3102A 28-11SZ Z-code
1 120-1824c Flange socket MS3102A 20-29SZ Z-code
1 120-0943 Cover size 28 Metal With chain.
1 120-0943d Cover size 20 Metal With chain.
28-11SZ-WDF 20-29SZ-WDF

Images cover size 20, 28

The angle coding is based on this illustration:

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WALL PENETRATIONS WDF

6.4.2 Angular position measuring system WMS with round connector M23 for WDF.R1 (Option)
We supply the wired device coupling as shown, with screw-on cover. Cable length 10 m.
For more diagrams corresponding to the different signal types used with the WMS, see chapter 9.2.

NOTE
Check plug compatibility.
Check conformity of harness with the machine!
In addition to connector type and coding, correct signal assignment is also decisive.
No changes may be made to the wiring harness.
The use of a complete wall penetration is possible at any time.

6.4.3 WDF.lo – wall penetration for air/oil


Connector AND coupling are supplied in bulkhead version G⅛".

Coupling for compressed air 6 bar (blue) on machine wall


X2DU1x = Interface for air
x=1=indexing axis , x=2=tiling axis
125-0613a coupling, blue, hexagonal, bulkhead version, Mfr.
TRIGRESS: 21KB TS 04 MPX6
2x included with T-systems.

Coupling for oil 0.4 bar (green)


X2PS1x = Interface for oil
125-0614a coupling, green, round bulkhead version, Mfr. TRIGRESS:
21KB TS 04 MPX0
2x included with T-systems.
Bleed the coupling.

Coupling for oil on maintenance unit


125-0081 sealing adapter, Fa Trigress. 20SBKO06MPX
1x supplied.

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SCHEMAS PNEUMATIC / HYDRAULIC

7 Pneumatic/hydraulic diagrams – STANDARD and OPTIONS


7.1 PH.EA-5xx (.RFX) – P/H diagram for EA and counter bearing

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SCHEMAS PNEUMATIC / HYDRAULIC

7.2 PH.Mx-5xx – P/H diagram for multiple modules

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SCHEMAS PNEUMATIC / HYDRAULIC

7.3 PH.TF…Tx-5xx5xx – P/H diagram for parts swivelling / tilting

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SCHEMAS PNEUMATIC / HYDRAULIC

7.4 Options «SPI.5xx-Lab» and «SPI.IP68»

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SCHEMAS ELECTRIC OVERVIEW

8 DIAGRAMS OVERVIEW - all electrical diagrams


The following tables contain all current standard and OEM wiring harnesses and all standard wall
penetrations with the associated diagrams.
The machine-specific servoPACK solutions are not listed. These are documented in separate manuals.
See at www.lehmann-rotary-table.com
The page numbers are active. Use the «Jump to page» function.

8.1 Wall penetrations WDF – pL-STANDARD

Motor K8 R1 Item no. Diagram no. Page


X WDF.WMS in connector HARTING Divers 88
WDF.WMS with connector M23 Divers 88
FANUC X WDF.Fx-K-2
FANUC X WDF.Fx-Kw-2
WDF.Fx-K(w)-2 and WDF.Fx-S(w)-2 88
FANUC X WDF.Fx-S-2
FANUC X WDF.Fx-Sw-2
FANUC X WDF.Fx-Rx-2 WDF.Fx-Rx-2 92
MAVILOR X WDF.M1-K-2
WDF.M1-K-2 and WDF.M1-S-2 77
MAVILOR X WDF.M1-S-2
MAVILOR X WDF.M2-K-2
WDF.M2-K-2 and WDF.M2-S-2 90
MAVILOR X WDF.M2-S-2
MAVILOR X WDF.M2-R1x-S-2 WDF.M2-R1x-S-2 93
MITSUBISHI X WDF.MI1-K-2
MITSUBISHI X WDF.MI1-Kw-2 WDF.MI1-K(w)-2 and WDF.MI1-S(w)-
91
MITSUBISHI X WDF.MI1-S-2 2
MITSUBISHI X WDF.MI1-Sw-2

8.2 Wiring harnesses KAB – pL-STANDARD


Motor K8 R1 o Item no Remarks Page
FANUC X KAB.Fx-x.x-K8x-2 99
CNC-FANUC X KAB.Fx-x.x-K8x-2 99
MAVILOR X KAB.M1-x.x-K8x-2 100
MAVILOR X KAB.M2-x.x-K8x-2 101
YASKAWA X KAB.Y2x-x.x-K8x-2 102
MITSUBISHI X KAB.MI1-x.x-K8x-2 103
WMS X KAB. … w-K8 1Vpp-EnDat_02 104

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SCHEMAS ELECTRIC OVERVIEW

Motor K8 R1 o Item no Remarks Page


WMS X KAB. … w-R1
WMS X KAB. … w-o 123
WMS X KAB. … w-K8
104
WMS X KAB. … w-R1 1Vpp
WMS X KAB. … w-o 123
WMS X KAB. … w-K8
104
WMS X KAB. … w-R1 5VTTL
WMS X KAB. … w-o 123
WMS X KAB. … w-K8
104
WMS X KAB. … w-R1 EnDat_22
WMS X KAB. … w-o 123
WMS X KAB. … w-K8
104
WMS X KAB. … w-R1 FANUC_02
WMS X KAB. … w-o 123
WMS X KAB. … w-K8
104
WMS X KAB. … w-R1 Mitsubishi
WMS X KAB. … w-o 123
FANUC X KAB.Fx-x.x-R1x-2 109
FANUC X KAB.Fx-x.x-R2x-2 110
MAVILOR X KAB.M2-x.x-R1x-2 111
MITSUBISHI X KAB.MI1-x.x-R1x-2 111
MITSUBISHI X KAB.MI2-x.x-R1x-2 113
YASKAWA X KAB.Y2x-x.x-R1x-2 114
FANUC X KAB.Fx-x.x-o-2 115
MAVILOR X KAB.M1-x.x-o-2 116
MAVILOR X KAB.M2-x.x-o-2 117
YASKAWA X KAB.Y1-x.x-o-2 118
YASKAWA X KAB.Y2-x.x-o-2 119
YASKAWA X KAB.Y2a-x.x-o-2 119
MITSUBISHI X KAB.MI1-x.x-2-o 120
MITSUBISHI X KAB.MI2-x.x-o-2 121
SANYO X KAB.SA-x.x-o-2 122
MAVILOR KAB.M1-x.x-MNC-2 129
YASKAWA KAB.Y3-x.x-MNC-2 130
KAB.2H 126

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SCHEMAS ELECTRIC OVERVIEW

8.3 KAB and WDF – specific for OEM's, in this document


Machine Schema no and item no Remarks Page
DMG KAB.F3-1.9-DMa-2 132
DMG 121.026a 1Vpp - zu DMb 133
DMG KAB.M1-1.7-DMb-2 135
DMG KAB.M1-1.7-DMb2-2 135
DMG STE.DMbw 1Vpp_EnDat 136
MATO WDF.Fx-K-MAa 137
MATO WDF.Mx-K-MAa
137
MATO WDF.Mx-Kw-MAa
MIKRON KAB.M1-x.x-MIa-2 139
MIKRON KAB.M1-x.x-MIb-2 140
MIKRON KAB.M1-x.x-MIc-2 141
MIKRON KAB.M1-x.x-Mid-2 142
MIKRON KAB.M1-x.x-MId2-2 143
MIKRON KAB.M1-x.xw-Mid2-2 144
BLOHM KAB.M1-x.x-BLO-2 2 blackBOX-Kabel 140
SCHAUBLIN SPEZ.KAB-SCa-2 147
MATSUURA KAB.Fx-x.x-MTa-2 148

8.4 Schematic diagrams, placed in other documents


See Chapter 10

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DIAGRAM OF STANDARD CABLING

9 Electrical – STANDARD cabling diagrams


Table of Contents
9.1 Diagrams for wall penetrations WDF with HARTING «K8» & free cable «o» ........................................................... 88
9.1.1 WDF.Fx-K(w)-2 and WDF.Fx-S(w)-2 – for FANUC () ................................................................................................. 88
9.1.2 WDF.M1-K-2 and WDF.M1-S-2 – for MAVILOR ERN incr. (SIEMENS+HEIDENHAIN) ()............................................ 89
9.1.3 WDF.M2-K-2 and WDF.M2-S-2 – for MAVILOR EQN abs. (SIEMENS+HEIDENHAIN) ()............................................ 90
9.1.4 WDF.MI1-K(w)-2 and WDF.MI1-S(w)-2 – for MITSUBISHI HF-KP................................................................................ 91
9.1.5 WDF.Fx-R1x-2 – for FANUC _i,is (F3) and _i,is (F4) ................................................................................................ 92
9.1.6 WDF.M2-R1x-S-2 – for motor MAVILOR/SIEMENS absolut coded (EQN) ................................................................... 93

9.2 Schemas for angle meas. Systems (WMS) on WDF stand with Harting (Option) ...................................................... 94
9.2.1 WDF.Mx-S(K)w-2-1Vpp_EnDat (SubD)........................................................................................................................ 94
9.2.2 WDF.Mx-S(K)w-2-1Vpp (SubD) ................................................................................................................................... 94
9.2.3 WDF.Mx-S(K)wd-2-CLiQ (RJ45) (Magnescale RU97-S) ................................................................................................ 95

9.3 Schemas for angle meas. systems (WMS) on WDF with connector M23 (option) .................................................... 95
9.3.1 WDF.WMS-1Vpp_EnDat (SubD).................................................................................................................................. 95
9.3.2 WDF.WMS-1Vpp (SubD) ............................................................................................................................................. 96
9.3.3 WDF.WMS-CliQ (RJ45) (Magnescale RU97-S) ............................................................................................................. 96
9.3.4 WDF.WMS-5VTTL (o) .................................................................................................................................................. 97
9.3.5 WDF.WMS-Mix (Connector Fabr. 3M SCR) ................................................................................................................. 97
9.3.6 WDF.WMS-Fx (Connector Fabr. PCR) ......................................................................................................................... 98

9.4 Diagrams for wiring harnesses KAB with connector HARTING «K8» ........................................................................ 99
9.4.1 KAB.Fx-x.x-K8x-2 – for motors FANUC α and β [CNC.xAX-FA] .................................................................................... 99
9.4.2 KAB.M1-x.x-K8x-2 – for motor MAVILOR ERN .......................................................................................................... 100
9.4.3 KAB.M2-x.x-K8x-2 – for motor MAVILOR EQN .......................................................................................................... 101
9.4.4 KAB.Y2x-x.x-K8x-2 – for motor YASKAWA SGMJV-04 (Y2a) and SGMJV-08 (Y2) ...................................................... 102
9.4.5 KAB.MI1-x.x-K8x-2 – for motor MITSUBISHI HF-KP .................................................................................................. 103
9.4.6 Option WMS 1Vpp-EnDat_02 for: KAB. … w-K8(R1) ................................................................................................. 104
9.4.7 Option WMS 1Vpp for: KAB. … w-K8(R1) .................................................................................................................. 104
9.4.8 Option WMS 5V_TTL for: KAB. … w-K8(R1) .............................................................................................................. 105
9.4.9 Option WMS EnDat_22 for: KAB. … w-K8(R1)........................................................................................................... 105
9.4.10 Option WMS DriveCLiQ SIEMENS for: KAB. … wd-K8(R1) (Magnescale RU97-S) ...................................................... 106
9.4.11 Option WMS FANUC for: KAB. … w-K8(R1) (HEIDENHAIN) ....................................................................................... 106
9.4.12 Option WMS FANUC for: KAB. … w-K8(R1) (Magnescale RU77-F) ............................................................................ 107
9.4.13 Option WMS MITSUBISHI for: KAB. … w-K8(R1) (HEIDENHAIN) ............................................................................... 107
9.4.14 Option WMS MITSUBISHI for: KAB. … w-K8(R1) (Magnescale RU77-M) .................................................................. 108
9.4.15 Option WMS YASKAWA für: KAB. … w-K8(R1) (Magnescale RU77-Y) ....................................................................... 108

9.5 Wiring diagrams of harnesses with round connectors «MIL» ................................................................................ 109
9.5.1 KAB.Fx-x.x-R1x-2 – for motors FANUC αi(s) and βi(s) ............................................................................................... 109
9.5.2 KAB.Fx-x.x-R2x-2 – for motors FANUC αi(s) und βi(s) ............................................................................................... 110
9.5.3 KAB.M2-x.x-R1x-2 – for motor MAVILOR/SIEMENS absolut coded (EQN) ............................................................... 111
9.5.4 KAB.MI1-x.x-R1x-2 – for motor MITSUBISHI HF-KP (DMG-MORI/AKIRA) ................................................................. 112
9.5.5 KAB.MI2-x.x-R1x-2 – Motor MITSUBISHI HF-(H)75S-A48; HF-(H)104S-A48 (DMG-MORI/AKIRA) ............................ 113
9.5.6 KAB.Y2 (and Y2a) -x.x-R1x-2 – for motor YASKAWA SGMJV-04 (Y2a) and SGMJV-08 (Y2) ....................................... 114

9.6 Diagrams Wiring harnesses KAB with «o» (= free cable ends) ............................................................................... 115
9.6.1 KAB.Fx-x.x-o-2 – for motor FANUC αi(s) and βi(s) .................................................................................................... 115
9.6.2 KAB.M1-x.x-o-2 – for motor MAVILOR ERN (SIEMENS 1FT6 incr.) (M1) ................................................................... 116
9.6.3 KAB.M2-x.x-o-2 – for motor MAVILOR EQN (SIEMENS 1FT6 abs.) (M2) ................................................................... 117
9.6.4 KAB.Y1-x.x-o-2 – for motor YASKAWA SGMAH (Y1) ................................................................................................. 118
9.6.5 KAB.Y2-x.x-o-2 [and] KAB.Y2a-x.x-o-2 – for Mot. YASKAWA SGMJV-08 (Y2) SGMJV-04 (Y2a) ................................. 119
9.6.6 KAB.MI1-x.x-o-2 – for motor MITSUBISHI HF-KP (MI1) ............................................................................................ 120
9.6.7 KAB.MI2-x.x-o-2 – for motor MITSUBISHI HF-(H)75S-A48 + HF-(H)104S-A48 (510…530) ........................................ 121

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DIAGRAM OF STANDARD CABLING

9.6.8 KAB.SA-x.x-o-2 – for motor SANYO x2AA0x0xxFXP00M ........................................................................................... 122


9.6.9 Option WMS for: KAB. … w-o (= free cable ends) (HEIDENHAIN) ............................................................................. 123
9.6.10 Option WMS for: KAB. … w-o (= free cable ends) (Magnescale RU77) ..................................................................... 124
9.6.11 Option WMS for: KAB. … w-o (= free cable ends) (Magnescale RU97) ..................................................................... 124

9.7 Connector set STE.xx for wiring harness STANDARD pL LEHMANN ........................................................................ 125

9.8 Expanding the wiring harness on your own ........................................................................................................... 126

9.9 Diagrams for CNC controls systems from pL LEHMANN ......................................................................................... 127
9.9.1 pL LEHMANN CNC «FANUC PMi» and «FANUC 35iB» – KAB.Fx-x.x-K8x-2 ............................................................... 127
9.9.2 Interface of pL LEHMANN CNC «FANUC PMi» and «FANUC 35iB» .......................................................................... 128
9.9.3 pL LEHMANN CNC «ModulaNC» - KAB.M1-x.x-MNC-2 ............................................................................................. 129
9.9.4 pL LEHMANN CNC «CPS» with cabling Han42DD - KAB.Y3-x.x-CPS-2 ....................................................................... 130

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DIAGRAM OF STANDARD CABLING

9.1 Diagrams for wall penetrations WDF with HARTING «K8» & free cable «o»
9.1.1 WDF.Fx-K(w)-2 and WDF.Fx-S(w)-2 – for FANUC ()

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DIAGRAM OF STANDARD CABLING

9.1.2 WDF.M1-K-2 and WDF.M1-S-2 – for MAVILOR ERN incr. (SIEMENS+HEIDENHAIN) ()

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DIAGRAM OF STANDARD CABLING

9.1.3 WDF.M2-K-2 and WDF.M2-S-2 – for MAVILOR EQN abs. (SIEMENS+HEIDENHAIN) ()

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DIAGRAM OF STANDARD CABLING

9.1.4 WDF.MI1-K(w)-2 and WDF.MI1-S(w)-2 – for MITSUBISHI HF-KP

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DIAGRAM OF STANDARD CABLING

9.1.5 WDF.Fx-R1x-2 – for FANUC _i,is (F3) and _i,is (F4)

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DIAGRAM OF STANDARD CABLING

9.1.6 WDF.M2-R1x-S-2 – for motor MAVILOR/SIEMENS absolut coded (EQN)

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DIAGRAM OF STANDARD CABLING

9.2 Schemas for angle meas. Systems (WMS) on WDF stand with Harting (Option)
9.2.1 WDF.Mx-S(K)w-2-1Vpp_EnDat (SubD)

9.2.2 WDF.Mx-S(K)w-2-1Vpp (SubD)

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DIAGRAM OF STANDARD CABLING

9.2.3 WDF.Mx-S(K)wd-2-CLiQ (RJ45) (Magnescale RU97-S)

9.3 Schemas for angle meas. systems (WMS) on WDF with connector M23 (option)
9.3.1 WDF.WMS-1Vpp_EnDat (SubD)

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DIAGRAM OF STANDARD CABLING

9.3.2 WDF.WMS-1Vpp (SubD)

9.3.3 WDF.WMS-CliQ (RJ45) (Magnescale RU97-S)

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9.3.4 WDF.WMS-5VTTL (o)

9.3.5 WDF.WMS-Mix (Connector Fabr. 3M SCR)

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DIAGRAM OF STANDARD CABLING

9.3.6 WDF.WMS-Fx (Connector Fabr. PCR)

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9.4 Diagrams for wiring harnesses KAB with connector HARTING «K8»
9.4.1 KAB.Fx-x.x-K8x-2 – for motors FANUC α and β [CNC.xAX-FA]
The FANUC 35iB CNC is wired according to this diagram.

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DIAGRAM OF STANDARD CABLING

9.4.2 KAB.M1-x.x-K8x-2 – for motor MAVILOR ERN

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9.4.3 KAB.M2-x.x-K8x-2 – for motor MAVILOR EQN

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DIAGRAM OF STANDARD CABLING

9.4.4 KAB.Y2x-x.x-K8x-2 – for motor YASKAWA SGMJV-04 (Y2a) and SGMJV-08 (Y2)

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9.4.5 KAB.MI1-x.x-K8x-2 – for motor MITSUBISHI HF-KP

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9.4.6 Option WMS 1Vpp-EnDat_02 for: KAB. … w-K8(R1)

9.4.7 Option WMS 1Vpp for: KAB. … w-K8(R1)

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9.4.8 Option WMS 5V_TTL for: KAB. … w-K8(R1)

9.4.9 Option WMS EnDat_22 for: KAB. … w-K8(R1)

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9.4.10 Option WMS DriveCLiQ SIEMENS for: KAB. … wd-K8(R1) (Magnescale RU97-S)

9.4.11 Option WMS FANUC for: KAB. … w-K8(R1) (HEIDENHAIN)

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9.4.12 Option WMS FANUC for: KAB. … w-K8(R1) (Magnescale RU77-F)

9.4.13 Option WMS MITSUBISHI for: KAB. … w-K8(R1) (HEIDENHAIN)

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9.4.14 Option WMS MITSUBISHI for: KAB. … w-K8(R1) (Magnescale RU77-M)

9.4.15 Option WMS YASKAWA für: KAB. … w-K8(R1) (Magnescale RU77-Y)

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9.5 Wiring diagrams of harnesses with round connectors «MIL»


9.5.1 KAB.Fx-x.x-R1x-2 – for motors FANUC αi(s) and βi(s)
This is the pL STANDARD cabling with MIL connectors. Main features:
► The signal «Clamp» (pin P-G) can be used for 24VDC or 110VAC.
► All signals on the blackBOX are connected to the machine.

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DIAGRAM OF STANDARD CABLING

9.5.2 KAB.Fx-x.x-R2x-2 – for motors FANUC αi(s) und βi(s)


This wiring with «R2x» in the designation is a variant of the pL STANDARD cabling with MIL connectors.
Difference to STANDARD «R1x»:
► The signal «Clamp» is wired for +24VDC. (0VDC and N of AC may NOT be combined.)
► Air and oil hoses are provided for direct connection to maintenance unit.

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9.5.3 KAB.M2-x.x-R1x-2 – for motor MAVILOR/SIEMENS absolut coded (EQN)

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9.5.4 KAB.MI1-x.x-R1x-2 – for motor MITSUBISHI HF-KP (DMG-MORI/AKIRA)


Please note: The pin assignment is coordinated with DMG MORI NVX5x and AKIRA.
For this reason, it may NOT be changed arbitrarily.

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9.5.5 KAB.MI2-x.x-R1x-2 – Motor MITSUBISHI HF-(H)75S-A48; HF-(H)104S-A48 (DMG-MORI/AKIRA)


Please note: The pin assignment is coordinated with DMG MORI NVX5x and AKIRA.
For this reason, it may NOT be changed arbitrarily.

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DIAGRAM OF STANDARD CABLING

9.5.6 KAB.Y2 (and Y2a) -x.x-R1x-2 – for motor YASKAWA SGMJV-04 (Y2a) and SGMJV-08 (Y2)

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9.6 Diagrams Wiring harnesses KAB with «o» (= free cable ends)
9.6.1 KAB.Fx-x.x-o-2 – for motor FANUC αi(s) and βi(s)

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9.6.2 KAB.M1-x.x-o-2 – for motor MAVILOR ERN (SIEMENS 1FT6 incr.) (M1)

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9.6.3 KAB.M2-x.x-o-2 – for motor MAVILOR EQN (SIEMENS 1FT6 abs.) (M2)

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9.6.4 KAB.Y1-x.x-o-2 – for motor YASKAWA SGMAH (Y1)

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9.6.5 KAB.Y2-x.x-o-2 [and] KAB.Y2a-x.x-o-2 – for Mot. YASKAWA SGMJV-08 (Y2) SGMJV-04 (Y2a)

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9.6.6 KAB.MI1-x.x-o-2 – for motor MITSUBISHI HF-KP (MI1)

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9.6.7 KAB.MI2-x.x-o-2 – for motor MITSUBISHI HF-(H)75S-A48 + HF-(H)104S-A48 (510…530)

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9.6.8 KAB.SA-x.x-o-2 – for motor SANYO x2AA0x0xxFXP00M

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9.6.9 Option WMS for: KAB. … w-o (= free cable ends) (HEIDENHAIN)

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9.6.10 Option WMS for: KAB. … w-o (= free cable ends) (Magnescale RU77)

9.6.11 Option WMS for: KAB. … w-o (= free cable ends) (Magnescale RU97)

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9.7 Connector set STE.xx for wiring harness STANDARD pL LEHMANN


The standard plugs scan be ordered under the following numbers.

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9.8 Expanding the wiring harness on your own

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9.9 Diagrams for CNC controls systems from pL LEHMANN


9.9.1 pL LEHMANN CNC «FANUC PMi» and «FANUC 35iB» – KAB.Fx-x.x-K8x-2

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9.9.2 Interface of pL LEHMANN CNC «FANUC PMi» and «FANUC 35iB»

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9.9.3 pL LEHMANN CNC «ModulaNC» - KAB.M1-x.x-MNC-2

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9.9.4 pL LEHMANN CNC «CPS» with cabling Han42DD - KAB.Y3-x.x-CPS-2

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10 DIAGRAMS for OEM electrical cabling


Table of Contents
10.1 DMG MORI ............................................................................................................................................................ 132
10.1.1 KAB.F3-x.x-DMa-2 – for DMC-xx35V with pL EA-5xx .............................................................................................. 132
10.1.2 Option WMS 1Vpp for: 121.026a ........................................................................................................................... 133
10.1.3 KAB.M1-1.7-DMb-2 – for DMF; DMU-50/70, -60/80; for pL EA-5xx ....................................................................... 134
10.1.4 KAB.M1-1.7-DMb2-2 – for DMF; DMU-50/70, -60/80; for pL tilter ........................................................................ 135
10.1.5 Option WMS 1Vpp-EnDat_02 for: STE.DMb........................................................................................................... 136
10.2 WALTER MEIER - MATO ......................................................................................................................................... 137
10.2.1 WDF.Fx-K(w)-MAa – for CNC-FANUC ..................................................................................................................... 137
10.2.2 WDF.Mx-K(w)-MAa – for CNC-HEIDENHAIN iTNC530 ............................................................................................ 138
10.3 MIKRON ................................................................................................................................................................ 139
10.3.1 KAB.M1-x.x-MIa-2 – for machine VCP_600/800 .................................................................................................... 139
10.3.2 KAB.M1-x.x-MIb-2 – for machine VCE ................................................................................................................... 140
10.3.3 KAB.M1-x.x-MIc-2 – for machine HSM and HPM ................................................................................................... 141
10.3.4 KAB.M1-x.x-MId-2, Dividing axis – for machine HSM and LP ................................................................................. 142
10.3.5 KAB.M1-x.x-MId2-2, Tiliting axis without WMS – for machine HSM and LP ........................................................... 143
10.3.6 KAB.M1-x.xw-MId2-2, Tiliting axis with WMS – for machine HSM and LP ............................................................. 144
10.3.7 KAB.Y2-x.x-MIc-2 [and] KAB.Y2a-x.x-MIc-2 – for Mot. YASK. SGMJV-08 (Y2) SGMJV-04 (Y2a) ............................... 145
10.4 BLOHM – KAB.M1-x.x-BLO-2 ................................................................................................................................. 146
10.5 SCHAUBLIN SPEZ.KAB-SCa-2 – special assignment KAB.Fx-x.x-R1 .......................................................................... 147
10.6 MATSUURA - KAB.Fx-x.x-MTx-2............................................................................................................................. 148
10.7 OKUMA - KAB.OK-x.x-Rx-2 .................................................................................................................................... 149
10.8 Akira-Seiki ............................................................................................................................................................. 150
10.9 BFW....................................................................................................................................................................... 150
10.10 Brother .................................................................................................................................................................. 150
10.11 DMGMori .............................................................................................................................................................. 150
10.12 DOOSAN ................................................................................................................................................................ 150
10.13 Fanuc ROBODRILL .................................................................................................................................................. 151
10.14 HAAS USA .............................................................................................................................................................. 151
10.15 HURCO .................................................................................................................................................................. 151
10.16 HYUNDAI ............................................................................................................................................................... 151
10.17 MAKINO ................................................................................................................................................................ 152
10.18 MAZAK .................................................................................................................................................................. 152
10.19 QUASER ................................................................................................................................................................. 152
10.20 TONGTAI ............................................................................................................................................................... 152
10.21 OKUMA ................................................................................................................................................................. 152

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10.1 DMG MORI


10.1.1 KAB.F3-x.x-DMa-2 – for DMC-xx35V with pL EA-5xx

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10.1.2 Option WMS 1Vpp for: 121.026a

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10.1.3 KAB.M1-1.7-DMb-2 – for DMF; DMU-50/70, -60/80; for pL EA-5xx

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10.1.4 KAB.M1-1.7-DMb2-2 – for DMF; DMU-50/70, -60/80; for pL tilter

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10.1.5 Option WMS 1Vpp-EnDat_02 for: STE.DMb

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10.2 WALTER MEIER - MATO


10.2.1 WDF.Fx-K(w)-MAa – for CNC-FANUC

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10.2.2 WDF.Mx-K(w)-MAa – for CNC-HEIDENHAIN iTNC530

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10.3 MIKRON
10.3.1 KAB.M1-x.x-MIa-2 – for machine VCP_600/800

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10.3.2 KAB.M1-x.x-MIb-2 – for machine VCE

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10.3.3 KAB.M1-x.x-MIc-2 – for machine HSM and HPM

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10.3.4 KAB.M1-x.x-MId-2, Dividing axis – for machine HSM and LP

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10.3.5 KAB.M1-x.x-MId2-2, Tiliting axis without WMS – for machine HSM and LP

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10.3.6 KAB.M1-x.xw-MId2-2, Tiliting axis with WMS – for machine HSM and LP

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10.3.7 KAB.Y2-x.x-MIc-2 [and] KAB.Y2a-x.x-MIc-2 – for Mot. YASK. SGMJV-08 (Y2) SGMJV-04 (Y2a)

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10.4 BLOHM – KAB.M1-x.x-BLO-2

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10.5 SCHAUBLIN SPEZ.KAB-SCa-2 – special assignment KAB.Fx-x.x-R1

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10.6 MATSUURA - KAB.Fx-x.x-MTx-2

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10.7 OKUMA - KAB.OK-x.x-Rx-2

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10.8 Akira-Seiki
Dokumen- Schema-Nr.
Maschine Typ Motor
tation und Bestell-Nr.
Akira Seiki DOK-0218 KAB.MI1-x.x.-R1x-2 MITSUBISHI HF-KP

10.9 BFW
Dokumen- Schema-Nr.
Maschine Typ Motor
tation und Bestell-Nr.
KAB.Fx-x.x-R2x-2
BFW DOK-0278 Fanuc
KAB.Fx-x.x-o-2

10.10 Brother
Dokumen- Schema-Nr.
Maschine Typ Motor
tation und Bestell-Nr.
BROTHER Rx50X1 DOK-0264 KAB.SA-x.x-BRa-2 Sanyo R2AA060 und R2AA080
BROTHER "SPEEDIO" DOK-0241 KAB.SA-x.x-BRa-2 Sanyo R2AA060 und R2AA080
BROTHER TC-22B DOK-0200 KAB.Y1-x.x-BRa-2 Yaskawa SGMAH
BROTHER TC-32BN-FT DOK-0201 KAB.Y1-x.x-BRa-2 Yaskawa SGMAH
BROTHER TC- 32BN-QT DOK-0195 KAB.Y1-x.x-BRa-2 Yaskawa SGMAH
BROTHER TC-R2B DOK-0192 KAB.SA-x.x-BRa-2 Sanyo R2AA060 und R2AA080
Brother TC-S2D(N) DOK-0191 KAB.SA-x.x-BRa-2 Sanyo R2AA060 und R2AA080

10.11 DMGMori
Dokumen- Schema-Nr.
Maschine Typ Motor
tation und Bestell-Nr.
KAB.M1-x.x-Dma-2 MAVILOR
DMGMori ecomill DOK-0279 KAB.M1-x.x-Dma2-2
MAVILOR
KAB.M1-x.x-Dmc-2
DMGMori NVX DOK-0215 KAB.MI1-x.x.-R1x-2 MITSUBISHI HF-KP

10.12 DOOSAN
Dokumen- Schema-Nr.
Maschine Typ Motor
tation und Bestell-Nr.
Akira Seiki DOK-0218 KAB.MI1-x.x.-R1x-2 MITSUBISHI HF-KP
KAB.Fx-x.x-R2x-2
BFW DOK-0278 Fanuc
KAB.Fx-x.x-o-2
BROTHER Rx50X1 DOK-0264 KAB.SA-x.x-BRa-2 Sanyo R2AA060 und R2AA080
KAB.Fx-x.x-DOa-2
Fanuc
KAB.Fx-x.x-DOa2-2
DOOSAN DNMx, Mynx, VM DOK-0225
KIAB.M1-x.x-DOa-2
MAVILOR
WDF.M1-DOa
KAB.Fx-x.x-DOa-2
DOOSAN VC430, VC510 DOK-0252 Fanuc
KAB.Fx-x.x-DOa2-2

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10.13 Fanuc ROBODRILL


Dokumen- Schema-Nr.
Maschine Typ Motor
tation und Bestell-Nr.
KAB.Fx-x.x-FAa2-2
α-D KAB.Fx-x.x-FAa-2
Fanuc ROBODRILL α-D21xiA(5) DOK-0276 Fanuc
α-D14xiA(5) KAB.Fx-x.x-FAbz-2
KAB.Fx-x.x-FAb-2
KAB.Y2-x.x-HAa-2 YASKAWA SGMJV-08
KAB.Y2a-x.x-HAa-2 YASKAWA SGMJV-04
HAAS DOK-0193
KAB.Y2b-x.x-HAa-2 YASKAWA SGMEV
KAB.Y3-x.x-HAa-2 YASKAWA SGM
KAB.Y2-x.x-HUb-2 YASKAWA SGMJV-08
HURCO VMXi DOK-0270
KAB.Y2a-x.x-HUb-2 YASKAWA SGMJV-04
HURCO VMX 24/30/42 DOK-0190 KAB.Y2-x.x-HUb-2 YASKAWA SGMJV-08
HYUNDAI Wia F-Series DOK-0288 KAB.Fx-x.x-R2x-2
KAB.Fx-x.x-MKa-2 Fanuc
MAKINO DOK-0277
KAB.Fx-x.x-MKaz-2
KAB.MI2-x.x-MZa-2 MITSUBISHI (400V)
MAZAK DOK-0243
KAB.MI1-x.x-MZa-2 MITSUBISHI (200V)
KAB.Fx-x.x-K8x-2 Fanuc
QUASER DOK-0275
KAB.M1-x.x-K8x-2
MAVILOR
TONGTAI DOK-0280 KAB.M1-x.x-K8x-2

10.14 HAAS USA


Dokumen- Schema-Nr.
Maschine Typ Motor
tation und Bestell-Nr.
KAB.Y2-x.x-HAa-2 YASKAWA SGMJV-08
KAB.Y2a-x.x-HAa-2 YASKAWA SGMJV-04
HAAS DOK-0193
KAB.Y2b-x.x-HAa-2 YASKAWA SGMEV
KAB.Y3-x.x-HAa-2 YASKAWA SGM

10.15 HURCO
Dokumen- Schema-Nr.
Maschine Typ Motor
tation und Bestell-Nr.
KAB.Y2-x.x-HUb-2 YASKAWA SGMJV-08
HURCO VMXi DOK-0270
KAB.Y2a-x.x-HUb-2 YASKAWA SGMJV-04
HURCO VMX 24/30/42 DOK-0190 KAB.Y2-x.x-HUb-2 YASKAWA SGMJV-08

10.16 HYUNDAI
Dokumen- Schema-Nr.
Maschine Typ Motor
tation und Bestell-Nr.
HYUNDAI Wia F-Series DOK-0288 KAB.Fx-x.x-R2x-2 Fanuc

Commiss-Instr+Schemas_STANDARD_DOK-0004-EN(30)_2017-07-03 - Translated document in accordance with MRL 2006/42/EC 151 / 153


DIAGRAM OF OEM CABLING

10.17 MAKINO
Dokumen- Schema-Nr.
Maschine Typ Motor
tation und Bestell-Nr.
KAB.Fx-x.x-MKa-2
MAKINO DOK-0277
KAB.Fx-x.x-MKaz-2

10.18 MAZAK
Dokumen- Schema-Nr.
Maschine Typ Motor
tation und Bestell-Nr.
KAB.MI2-x.x-MZa-2 MITSUBISHI (400V)
MAZAK DOK-0243
KAB.MI1-x.x-MZa-2 MITSUBISHI (200V)

10.19 QUASER
Dokumen- Schema-Nr.
Maschine Typ Motor
tation und Bestell-Nr.
KAB.Fx-x.x-K8x-2 Fanuc
QUASER DOK-0275
KAB.M1-x.x-K8x-2 MAVILOR

10.20 TONGTAI
Dokumen- Schema-Nr.
Maschine Typ Motor
tation und Bestell-Nr.
TONGTAI DOK-0280 KAB.M1-x.x-K8x-2

10.21 OKUMA
Dokumen- Schema-Nr.
Maschine Typ Motor
tation und Bestell-Nr.
OKUMA Seite 149 KAB.M1-x.x-K8x-2 OKUMA

152 / 153 Commiss-Instr+Schemas_STANDARD_DOK-0004-EN(30)_2017-07-03 - Translated document in accordance with MRL 2006/42/EC


CONTACT

11 Contact
Manufacturer:
Peter Lehmann AG
Bäraustrasse 43
CH-3552 Bärau
+41 (0)34 409 66 66
+41 (0)34 409 66 00
pls@plehmann.com
www.lehmann-rotary-tables.com

Thank you for using pL LEHMANN products!

Commiss-Instr+Schemas_STANDARD_DOK-0004-EN(30)_2017-07-03 - Original document in accordance with MRL 2006/42/EG 153 / 153

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