Zimmer LKE Series User manual

INSTALLATION AND OPERATING INSTRUCTIONS: Clamping element, electric, LKE series
Zimmer GmbH • Im Salmenkopf 5 • D-77866 Rheinau, Germany • Phone:[phone] • Fax: [phone] • www.zimmer-group.de
Installation and
operating instructions
LKE
DDOC00215
Index d
EN / 2019-05-16
Im Salmenkopf
77866 Rheinau, Germany
[phone]
Fax: [phone]
www.zimmer-group.de
6 Connections
The element is connected via an 8-pin M12x1 plug cable.
7 Installation
NOTE:
Ensure accessibility for emergency actuation 7and of the adjustment screw 9of the element.
The element does not have any guide characteristics!
►Check the element for any damage before installing it.
• The element may only be used in conjunction with linear rail carriages.
►The mounting surface of the element (sliding block 6+ terminal box 4) has to be completely covered by the
mounting piece.
This enables the maximum possible holding force to build up. The adjacent motor housing bl does not have to be covered
by the mounting piece.
• Make sure the mounting pieces are suciently rigid (refer to section 7.1).
• Install the element using 4 screws.
• Use screws with a minimum strength class of 8.8.
Observe tightening torques http://www.schrauben-normen.de/anziehmomente.html  DIN 912 or ISO 4762
• Note the screw-in depth of the screws. If the screws are screwed in too far, they can block the oating
bearing Malfunction
7.1 Design of the mounting piece
INFORMATION:
The holding force is the maximum force that can be generated in the axial direction.
The specied holding forces are tested on every clamping and braking element before delivery using a slightly
lubricated rail (ISO VG 68). Using other oil or lubricating substances can inuence the coecient of friction, which
can cause a loss of holding force in individual cases.
In course of further development, technical changes are reserved.
NOTE:
Make sure the mounting piece is suciently rigid.
The user alone is responsible to ensure that the mounting piece is suciently rigid in terms of the 2006/42/
EC Machinery Directive. ZIMMER GmbH accepts no liability for any subsequent damage to the element or
subsequent injuries to persons.
►Make sure that the mounting faces (sliding block 6) are at (0,03 mm).
►The roughness of the surface (contact surface) of the
mounting piece should not exceed the value Ra = 3,2 µm.
►The extension cord, which lengthens the connecting cable 8,
must not exceed a length of 10 m and must be shielded.
►The electric connecting cable 8must be relieved of strain at
the mounting piece. The cable must be installed in such a way
that the cable cannot rub against the rail or get pinched.
► The 3D data for the prole rails is not necessarily true to detail
in the area of the rail groove. Refer to the catalog or product
selection on our website (www.zimmer-group.com/com/plt) to
see whether an element ts on the selected rail.
7.2 Installation procedure
NOTE:
If the mounting screws are tightened when the element is not closed, the element can shift and therefore be
unable to achieve the optimum holding force! Furthermore, the guide rail could become damaged.
INFORMATION:
The element is allowed to be closed only if the associated prole rail is between the contact surfaces!
• There must be no control voltage present when an electrical connecting cable 8is connected or
disconnected!
• Avoid changing signals before the specified time (opening/closing), otherwise there may be a malfunction.
• Unauthorized opening of the housing shall void any warranty claim.
If the element is not yet connected to a power supply, the element can be opened and closed manually using the
emergency actuation 7.
Turning counterclockwise = close
Turning clockwise = open
►Set the element on the linear guide.
If a spacer plate is used, it is inserted between the element
and the mounting piece as level compensation.
►Screw the screws into the tapped holes of the sliding block 6
and tighten them only slightly.
►The element centers itself as a result of a single cycle.
►Close the element.
► Tighten the mounting screws crosswise using the specied
torque.
►Open the element.
1White DIR signal, open=1 (24V)/close=0 (0V)
2Brown Output status “closed”
3Green Output status "error"
4Yellow Voltage supply 24 V / Logic
5Grey Output status “open”
6Pink Voltage supply 24 V / Motor
7Blue Not connect
8Red Voltage supply 0 V / GND
1 Supporting documents
NOTE:
The documents mentioned below are available for download on our website www.zimmer-group.de. Only the
documents currently available on the website are valid.
• Catalogs, drawings, CAD data, technical data
• Detailed installation and operating instructions
• General Terms and Conditions of Business with specications for the warranty entitlement
2 Safety notes
CAUTION:
Non-compliance may result in severe injuries!
Injuries/malfunctions can occur especially with:
• Crushing during installation due to an unsecured mounting piece
Protection against crushing as a result of low element stroke (max. 0,4 mm).
Protection by the use of bistable design engineering.
• Missing or loose mounting screws
• Failure to switch o the working medium during assembly or repair work on the element
• Human error
• Failure to observe the safety and warning instructions during installation and start-up
These installation and operating instructions are intended for installation and maintenance technicians as
well as design engineers requiring the element for an application. Please read all installation and operation
instructions carefully before start-up and pay special attention to the following hazard warnings and notes.
3 Proper use
NOTE:
The element should only be used in its original state with its original accessories, without any unauthorized
changes and within the scope of the dened parameters for use. Zimmer GmbH shall accept no liability for any
damage caused by improper use.
In accordance with EN ISO 13849-1, the LKE element is a safety-related component of control systems. Furthermore, we
can conrm the manufacture of the product using the basic and proven safety principles (Appendix D.1 and D.2 of EN
13849-2) and thus dene the LKE element as a proven component in accordance with EN 13849-1, Chap. 6.2.4, Par. b).
The element can be used without any control engineering measures in control systems of Category B or 1; for category 2
control systems, a test channel must be provided. For use in higher control categories, the control must be implemented
using multiple channels, where each channel must implement the safety function for itself.
The element may not be used in any application other than those approved by the manufacturer.
Without additional protection or control engineering measures, the element may not:
• be installed in facilities that are used for transporting people (e.g. elevators).
• be used in vehicles.
• be used underwater or in other uids.
• be used in a corrosive environment (for example, in connection with acids).
• come in contact with abrasive media (such as grinding dust).
• come in direct contact with food.
• be used in areas with a potentially explosive atmosphere.
For questions regarding use of the LKE series element, please contact Zimmer GmbH.
4 Personnelqualication
DANGER:
Never open the housing. Intervention is not permitted and can lead to serious injuries!
Warranty and disclaimer.
The manufacturer, ZIMMER GmbH, accepts no liability in the event of damage to property or injuries to
persons.
The installation, start-up, maintenance and repairs may be undertaken only in accordance with these installation and
operating instructions and only by qualied personnel who have the professional expertise and know the conditions, as
well as the dangers, of the machine into which the element is being installed.
5 Product description
The element of the LKE series is a bistable element and is designed for static clamping or xing of system components on
prole rail guides. Based on the self-locking functional principle, when the clamp is closed there is no need for any supply
voltage for the actuator to maintain the holding force. This means that in an open state, the only signal present is the DIR
signal (refer to the table found under Point 6, “Connections”).
Fig. 1: LKE element
Fig. 2: LKE element cutaway view
The element is provided with a serial number bn. The serial number
bn is located on the housing of the element. If possible, use this serial
number bn with your project and/or end customer to achieve a clear
and, above all, consistent assignment in the event of an update or
overhaul.
The part number bm can be found using the serial number bn.
NOTE:
The clamping process during a movement (dynamic) can lead to destruction or damage of the prole rail or the
element itself.
1Prole rail guide
2Eccentric gear
3Clamping jaws
4Housing
5Electric drive
6Sliding block
7Emergency actuation
8Electrical connecting cable
9Adjustment screw
10 Motor housing

INSTALLATION AND OPERATING INSTRUCTIONS: Clamping element, electric, LKE series
Zimmer GmbH • Im Salmenkopf 5 • D-77866 Rheinau, Germany • Phone:[phone] • Fax: [phone] • www.zimmer-group.de
Installation and
operating instructions
LKE
DDOC00215
Index d
EN / 2019-05-16
Im Salmenkopf
77866 Rheinau, Germany
[phone]
Fax: [phone]
www.zimmer-group.de
7.3 Tolerance compensation
The prole rails have a conventional tolerance of ± 0,05 mm. The
adjustment screw 9 for the passive contact prole can be used to
compensate this tolerance and achieve a centered positioning for the
element.
►You can use an Allen key to turn the adjustment screw 9and
adjust the element to the measured dimension of the rail.
► This adjustment is to be set and checked before nal assembly
of the element.
The centered setting of the element for the prole rail has a critical
inuence on achieving the maximum possible holding force.
Three markings are engraved on the housing of the element.
Marking fm:Nominal dimension of the rail (xx,xx)
Marking fn: Nominal dimension of + 0,05 mm
Marking fo: Nominal dimension of - 0,05 mm
The adjustment screw must not be turned using force
abovethespeciedtolerancesof±0,05mm!
7.4 Manual emergency actuation
CAUTION:
An injury hazard exists (crushing) with the use of emergency actuation
with an Allen key.
When using the emergency actuation, make sure that there is
sucient space for persons and tools in the surroundings where
movement takes place.
Observe the movement range of the eccentric shaft indicated by
the identier on the housing 7!
O = Open
C = Close
The element oers the possibility of being manually clamped or opened in the event of a failure of the electrical
system.
For this purpose there is a hexagon socket on the front side of the eccentric shaft 7. An Allen key can be used
here to move the element.
Turning counterclockwise = close
Turning clockwise = open
7.5 Disassembly
Disassembly is carried out in the reverse order of that described in sections 7.1 and 7.2.
7.6 Function check
After the element has been properly installed, check whether it is ready to be operated according to the following
characteristics:
• Check whether the element moves freely, perpendicular to the rail, by manually sliding the element
 When doing so, ensure that the oating bearing 6moves freely.
• Check whether the element moves freely on the prole rail by manually sliding the rail carriages.
• Check the clamping process by manually applying force against the closed element.
When doing so, the maximum holding force must not be exceeded.
• Visually inspect the entire connecting cable to make sure it is properly installed.
• Check all mounting screws for the specied tightening torque.
8 Maintenance
The element is maintenance-free for up to 500,000 cycles. Operating time may be reduced in the following circumstances:
• Non-compliance with operating parameters.
• No proper installation.
Even though the element is, as mentioned, maintenance-free, perform a regular visual inspection to check for corrosion,
damage and contamination.
9 Technical data
INFORMATION:
Please refer to our website www.zimmer-group.com/com/lt-td for technical data.
If you should have further questions about products or technical data, please contact ZIMMER GmbH
customer service.
For this purpose, please call our technology hotline at  [phone].
10 Accessories
11 Function table / Behavior / Process charts
11.1 Function table
1 = "high" = there is a signal = a voltage of 24 V is present.
0 = "low" = there is no signal = there is no voltage (0 V).
*) The clamp has an undened status (not "OPEN" and/or "CLOSED").
Example:
A signal failure may occur as a result of overvoltage (e.g. after closing or opening).
This means that there is no signal at the respective PIN (not “1” or “0”).
11.2 Behavior for “Voltage ON”
► From an undened position: The element always tries to open rst, then it executes the pending move
command. A permanent signal is output in this status at the "Error" output (PIN 3).
►From a defined position:
The element stays in the position in front of "Voltage OFF". The DIR signal has to change before the new
move command can be executed.
Article number Designation Version Length [m]
KAG1000B8 Connecting cable Straight 10
KAW1000B8 Connecting cable 90° angle 10
PIN 5 output
“open”
PIN 2 output
“closed”
PIN 3 output
“Error” Status / description
0 0 0 Status undened / actuator in motion
100The element is open
010The element is closed
0/1* 0/1* 1 Error
11.3 Process charts
Signal for change of direction (DIR signal, PIN 1) after "Voltage OFF"
To achieve the desired status, a signal change is required when the operating voltage is switched on.
Signal (DIR signal, PIN 1) during opening
 The element begins the opening process after a signal change from “Low to High” (0 V to 24 V).
Signal (DIR signal, PIN 1) during closing
 The element begins the closing process after a signal change from “High to Low” (24 V to 0 V).
12 Troubleshooting
INFORMATION:
If the described measures for corrective actions are unsuccessful, contact the customer service department at
ZIMMER GmbH.
•Technology hotline  [phone]
or
•Electronics hotline  [phone]
13 Transportation/storage
INFORMATION:
Never transport the clamping element when it is clamped and mounted. The elements and/or oating bearing
could become damaged in the process.
The clamping element is to be transported and stored only in the packaging supplied by Zimmer GmbH. If the element is
stored or transported dierently, an agent for corrosion protection must be provided as a precaution.
14 Declaration of Conformity
in terms of the EU Machinery Directive 2006/42/EC (Annex II 1 A)
Name and address of the manufacturer:
ZIMMER GmbH • Im Salmenkopf 5 • D-77866 Rheinau, Germany • Phone: [phone] • Fax: [phone] •
www.zimmer-group.de
We hereby declare that, as incomplete machines, the following, identically constructed elements
Product designation: Clamping element, electric
Type designation: LKE
conform to the requirements of the 2006/42/EC directive in their design and the version we put on the market.
The following harmonized standards have been used: (The manufacturer has a full list of the applied standards.)
DIN EN ISO 12100:2011-03 Safety of machinery – General principles – Risk assessment and risk reduction
DIN EN ISO 13849-1 / 2 Safety of machinery – Safety-related parts of control systems
DIN EN 62061 Safety of machinery: Functional safety of electrical, electronic and programmable electronic
control systems
DIN EN ISO 13732-1 Ergonomics of the thermal environment – Methods for the assessment of human
responses to contacts with surfaces – Part 1: Hot surfaces
Authorized representative for compiling
the relevant documents:
Voltage
24V
DIR signal
Opening time Closing time
Change at the D input from 0V to 24V
Element moves “Open”
Change at the D input from 24V to 0V
Element moves “Closed”
0V
24V (open)
0V (close)
OPEN
CLOSED
Output
OPEN
CLOSED
Element
Michael Hemler (see manufacturer's address) Rheinau, Germany 2018-07-18 Martin Zimmer
First name, last name Address Place and date of issuance (Legally binding signature)