Service Manual - English

_ Service Manual - English
Service Manual Ceramill Motion2 Contents
Amann Girrbach AG Page 1 of 92

Head Office
Amann Girrbach AG
Herrschaftswiesen 1
6842 Koblach | Austria
Tel.: +43 (0) 5523 62333-0
Fax: +43 (0) 5523 55990
austria@amanngirrbach.com
Subsidiary
Amann Girrbach GmbH

Dürrenweg 40
75177 Pforzheim | Germany
Tel.: +49 (0) 7231 957-100
Fax: +49 (0) 7231 957-159
germany@amanngirrbach.com
Subsidiary
Amann Girrbach America, Inc.

12169 Villa Road | Spring Hill
FL 34609 | USA
Toll-Free: 1-800 851 3719
Fax: (001) 352 398 1409
america@amanngirrbach.com
Subject to changes due to technical improvements!
These instructions cover 92 pages. If there are any pages or parts of the instructions missing, please contact the
manufacturer at the address given above.
Copyright by: © Amann Girrbach AG 2012

Contents
1. General ................................................................................................................................. 6
1.1 About this manual ......................................................................................................................................... 6
1.2 Qualification of the service personnel........................................................................................................... 6
1.3 Manufacturer service .................................................................................................................................... 6
1.4 Returns to Amann Girrbach .......................................................................................................................... 7
2. Basic instructions ................................................................................................................ 8

2.1 Safety instructions of this manual and their significance .............................................................................. 8
2.2 Other instructions .......................................................................................................................................... 9
2.3 Preparation before the service ..................................................................................................................... 9
2.4 Positioning information left/right ................................................................................................................... 9
2.5 During disassembly/assembly .................................................................................................................... 10
2.6 After completion of the service work ........................................................................................................... 10
2.7 Meaning of the symbols and font styles used............................................................................................. 10
3. Ceramill Motion2 parts overview ...................................................................................... 11
4. Disassembly of the side panels........................................................................................ 13
5. Disassembly of the side panel.......................................................................................... 14
6. Disassembly/assembly of the door .................................................................................. 15

6.1. Disassembly of the door ............................................................................................................................ 15
6.2. Assembly of the door ................................................................................................................................. 15
7. Disassembly of the control system .................................................................................. 16
8. Disassembly/assembly of the switch mounting plate .................................................... 17

8.1. Disassembly .............................................................................................................................................. 17
8.2. Assembly ................................................................................................................................................... 17
9. Disassembly of the housing ............................................................................................. 18

9.1. Disassembly .............................................................................................................................................. 18
9.1. Assembly ................................................................................................................................................... 18
10. Inserting the test pin........................................................................................................ 19
11. Replacing the spindle ...................................................................................................... 20

11.1 Disassembly of the spindle ....................................................................................................................... 20
11.2 Assembly of the spindle ............................................................................................................................ 23
11.3. Setting the sealing air .............................................................................................................................. 24
12. Replacing the bellows ..................................................................................................... 25

12.1. Disassembly of the bellows ..................................................................................................................... 25
12.2. Assembly of the bellows .......................................................................................................................... 25
13. Replacing the air control valve ....................................................................................... 27
14. Checking the air control valve ........................................................................................ 28
15. Replacing the solenoid valve .......................................................................................... 30

16. Replacing the length measurement unit ........................................................................ 31

16.1. Disassembly of the length measurement unit ......................................................................................... 31
16.2. Assembly of the length measurement unit .............................................................................................. 31
17. Replacing the A-axis rotary table ................................................................................... 32

17.1. Disassembly of the rotary table ............................................................................................................... 32
17.2. Assembly of the rotary table .................................................................................................................... 33
18. Replacing the B-axis rotary table ................................................................................... 34

18.1 Disassembly of the rotary table ................................................................................................................ 34
18.2 Assembly of the rotary table ..................................................................................................................... 35
19. Replacing the tool sensor ............................................................................................... 36

19.1 Disassembly of the tool sensor ................................................................................................................. 36
19.2 Assembly of the tool sensor ..................................................................................................................... 37
20. Replacing the encoder .................................................................................................... 38

20.1 Disassembly of the encoder ..................................................................................................................... 38
20.1 Assembly of the encoder .......................................................................................................................... 38
21. Replacing the 3-axis module .......................................................................................... 39

21.1. Disassembly of the 3-axis module ........................................................................................................... 39
21.2. Assembly of the 3-axis module ................................................................................................................ 40
21.3 Disassembly of the angle bracket............................................................................................................. 41
22. Alignment of the B-axis ................................................................................................... 42

22.1. Preparation for alignment ........................................................................................................................ 42
22.2. Axis alignment ......................................................................................................................................... 42
22.3. Pre-alignment of the angle bracket.......................................................................................................... 44
23. Spindle blocking aid ........................................................................................................ 46
24. Angle adjustment of the B-axis ..................................................................................... 47

24.1. Preparation for angle adjustment ............................................................................................................ 47
24.2. Setting the angle ...................................................................................................................................... 47
25. Adjustment of a horizontally inclined position of the A-axis ....................................... 51
26. Ceramill Motion service programme .............................................................................. 54

26.1. Start of the service programme ............................................................................................................... 54
26.2. Ceramill Motion service programme ........................................................................................................ 55
26.3. Activating operation with door open ........................................................................................................ 56
27. Ceramill Motion service programme procedures ......................................................... 57

27.1. Moving to the reference position ............................................................................................................. 57
26.2. Controlling the axes ................................................................................................................................. 57
27.3. Opening and closing the chuck ............................................................................................................... 60
27.4. Moving to the blank holder replacement position .................................................................................... 60
27.4. Calibration settings aid programme ......................................................................................................... 60

28. Determining the machine parameters ............................................................................ 62

28.1. A-axis zero point ...................................................................................................................................... 62
28.2. X/Y zero point .......................................................................................................................................... 67
28.3. Tool 1 - Tool check .................................................................................................................................. 71
28.4. Tool 1 Tool pick-up position........................................................................................................... 74
28.5. Tool length measurement ........................................................................................................................ 77
28.6. Blank zero point ....................................................................................................................................... 79
28.7. Tool change function check ..................................................................................................................... 81
28.8. Deactivating operation with open door .................................................................................................... 82
29. Milling test blocks ............................................................................................................ 83

29.1. Blank configuration .................................................................................................................................. 83
29.2. Loading the test block programme and milling ........................................................................................ 83
29.3. Measurement of the test blocks + adjustment of the machine parameters .............................................86
29.3. Determining the test block offset situation ............................................................................................... 91
29.4. Measuring the test block offset ................................................................................................................ 91

Service Manual Ceramill Motion2 General
1. General
1.1 About this manual
This service manual describes the work required to exchange the components and modules on the Ceramill
Motion 2 that are defined as replacement parts.
The layout of the instructions is as follows:
First the safety instructions and general instructions for working with this manual and for repair of the Ceramill
Motion 2 are provided in Section 2.
Section 3 provides a rough overview of the machine and the components intended as replacement parts.
Section 4 onwards describes the replacement of the components.
Section 25 onwards describes the determination and setting of the machine parameters in the service
programme of the Ceramill Motion 2.
1.2 Qualification of the service personnel
Repair of the Ceramill Motion 2 should only be carried out by personnel, who have been trained and qualified by
Amann Girrbach AG for this type of repair work!
Amann Girrbach does not accept any liability for damage to the Ceramill Motion 2 or for consequential damage,
which occurs as a result of improper or incorrect maintenance or repair work!
Information about the contents and requirements of the Ceramill Motion 2 service technique training is available
from our headquarters:
Amann Girrbach AG
Herrschaftswiesen 1
6842 Koblach | Austria
Tel.: +43 (0) 5523 62333-0
austria@amanngirrbach.com
1.3 Manufacturer service
Please contact our technical service directly if there are any questions or suggestions regarding repair of the
machine:
Amann Girrbach GmbH

Technical service
Dürrenweg 40
75177 Pforzheim | Germany
Tel.: +49 (0) 7231 957-021
germany@amanngirrbach.com

Service Manual Ceramill Motion2 General
Our Ceramill helpdesk is available to answer any questions about the use of the Ceramill Motion 2:
DE Tel.: +49 7231 957-100

AT Tel.: +43 5523 62333-390
INT Tel.: +43 5523 62333-399
1.4 Returns to Amann Girrbach
Return the replaced components together with the completed service log to our technical service.
Please use the original packaging of the components for transport.
If the complete machine has to be sent for repair, please contact our technical service directly first.

Service Manual Ceramill Motion2 Basic instructions
2. Basic instructions
It is essential to follow the safety instructions when repairing the Ceramill Motion 2!
The aim of the safety instructions is to ensure occupational safety, prevention of accidents and should avoid
damage to the product.
Other instructions are intended to facilitate repair of the Ceramill Motion 2.
2.1 Safety instructions of this manual and their significance
Remove the mains plug before opening

the housing.
Disconnect the compressed air supply.
Disconnect the PC connection.
The mains plug must be removed each time before opening the Ceramill Motion 2 housing!
The compressed air supply and connection to the PC should also be disconnected.
There is the risk of becoming jammed when moving the machine.

Care and forward planning are required when operating the machine.
No collision checks are carried out by the programme during movement of the axes when operating the machine
from the service programme!
The components and measurement tools could be damaged if collisions occur.
Set the axes speed of movement to the lowest level and proceed gradually to the measuring positions.
Keep hands out of the interior of the machine when moving the axes.
Ensure that you are electrostatically

discharged before beginning work.
Electrostatic discharge (abbreviated ESD) is a spark or discharge created in an electrically isolated material by
a large potential difference, which causes a very short, high electrical current impulse.
Even the slightest ESD effects, which are imperceptible for humans, can result in malfunctions, shortened service
life or total failure of the electronics.
When working with electronic components and circuits avoid handling packaging foam, plastic packaging
materials and conventional plastics in general.
Only touch electronic components if it is absolutely necessary.
If work has to be carried out on the control system, it is essential that service personnel attempt to discharge
static electricity beforehand on metallic water or heating pipes.

This safety instruction indicates a

dangerous situation, which can result in
damage to property.
2.2 Other instructions
Diverse instructions
Instructions for carrying out professional servicing as well as special features and suggestions for simplifying
disassembly and assembly work on the Ceramill Motion.
2.3 Preparation before the service
Placing the Ceramill Motion 2 on the Ceramill Coolstream as a tower version is only designed for
the normal operation of the machine.
It is essential that the Ceramill Motion 2 is removed from the Ceramill Coolstream and placed on a
stable worktop for servicing work!
2.4 Positioning information left/right
Instructions regarding positions in the unit as an orientation aid and directional indications always refer to the
machine when viewed from the front.

2.5 During disassembly/assembly
Make reference marks on the machine regarding the current settings for the alignment of the axes, the respective
wire routing in the machine and the plug connections of any wires that belong together. This facilitates
reassembly.
Disassembly will always be described precisely. If no further instructions are given regarding assembly, proceed
in reverse sequence to the disassembly when reassembling. A different procedure and special instructions
regarding assembly are described at the end of disassembly.
2.6 After completion of the service work
Check that all mountings are fitted securely.

When routing wires take care to ensure there are no possible collision or abrasion areas during
movement of the axes (it is better to secure too many than too few cable ties).
Check that the machine is functioning correctly.
2.7 Meaning of the symbols and font styles used
Handling instructions:
Directly describes an activity to be performed.
Cross reference:
Cross reference to an action or chain of actions in the respective listed section.
It involves repeatedly recurring activities, which are described once.
 Bullet symbol
Descriptions in bold
Menu items, selection fields and buttons in the programme are indicated in descriptions of the service
programme and descriptions for determining the machine parameters.
These terms are in bold.
Descriptions in italics
If the service programme requires specific inputs, these inputs are shown in italics in the description.

Service Manual Ceramill Motion2 Parts overview
3. Ceramill Motion2 parts

overview
No. Name
1 Door
2 Housing
3 Side panel right
4 Angle bracket with a-axis rotary table
5 Tool sensor
6 Blank holder
7 Switch mounting plate
8 Length measurement unit
9 Spindle
10 Bellows
11 Control system
12 Air control valve
13 Solenoid valve
14 B-axis rotary table
15 3-axis module

Service Manual Ceramill Motion2
- Blank page -

Service Manual Ceramill Motion2 Disassembly of the side panels
4. Disassembly of the side

panels

the housing!
Disconnect the compressed air supply!
Remove the 3 screws on each side panel.
Tip the side panel slightly away from the machine.

Remove the earthing wire from the side panel [1]

Service Manual Ceramill Motion2 Disassembly of the side panel
5. Disassembly of the side

panel

the housing!
Unplug the compressed air hose from the service

unit.
Remove the 6 screws on the back panel.
Tip the back panel slightly away from the
machine.
Remove the earthing wire from the back panel.

Service Manual Ceramill Motion2 Disassembly/assembly of the door
6. Disassembly/assembly of
the door
6.1. Disassembly of the door
Open the door.

Remove the 2 screws each on both sides of the
door.
6.2. Assembly of the door
Secure the door loosely using the 4 M6 x 12 torx

screws.
Do not tighten the screws at this stage!
Place the two alignment aids [1] with the stop lug
[2] facing down and towards the front on the
sealing framework.
Carefully close the door
The alignment aid lies on the sealing

surface of the door and the housing.
This optimally aligns the door.
Begin at one side, pull the door stay [3] towards

the door using the fingers [2], at the same time
press the door with the alignment aid underneath
onto the housing [4]
Tighten the screws with the other hand [5].
Repeat the working stages on the opposite side.
Then check the seal integrity of the door using the
“Seal check” programme.
If the door leaks, adjust the alignment

of the door!

Service Manual Ceramill Motion2 Disassembly of the control system
7. Disassembly of the control

system

the housing!

discharged before beginning work!
Disassembly of the side panels

Disassembly of the back panel
Disconnect all plug connections to the control
system.
Remove the 4 screws [1] on the underside of the
control system.
Pull the control system towards the back out of
the machine.
If the control system cannot be pulled

out, loosen the retention screws of the
housing at the back [2]. Then lift the
housing slightly and pull the control
system towards the back out of the
machine!
The following steps must also be completed when

replacing the control system:
Remove the SD card from the old control system

and insert it in the new control system [3].
The SD cards contain the respective

user data and must not be mixed up!
Enter the serial numbers of the old control system

and the new control system in the service log.

Service Manual Ceramill Motion2 Disassembly/assembly of the switch mounting plate
8. Disassembly/assembly of
the switch mounting plate

the housing!
8.1. Disassembly
Remove the two screws on the underside of the

switch mounting plate.
Then tip the switch mounting plate slightly
upwards and remove it from the housing.
Disconnect the plug connections to the two control
keys [1].
Remove the earthing wire [2].
8.2. Assembly
Connect the wires of the control keys and the

earthing wire.
Place the switch mounting plate at an angle onto
the housing and slide it as far as it will go under
the sealing lip of the sealing frame [3].
Rotate the switch mounting plate downwards into
place.
Ensure that the sealing lip [3] is

uniformly adapted to the switch
mounting plate!
Secure the two screws on the underside of the

switch mounting plate.

Service Manual Ceramill Motion2 Disassembly/assembly of the housing
9. Disassembly of the housing

the housing!
9.1. Disassembly

Disassembly of the door
Disassembly of the switch mounting plate
Remove the 6 screws on the housing [1], [2], [3].

Pull the housing forward slightly to create access
to the earthing wire.
Remove the earthing wire.
Remove the housing completely from the
machine.
9.1. Assembly
Place the housing on the machine and attach the

earthing wire.
Slide the housing towards the back carefully as far
as it will go [4].
Take care with the wires on the housing

and in the machine!
Insert the screws in the given sequence

[1], [2], [3].

Service Manual Ceramill Motion2 Inserting the test pin
10. Inserting the test pin

Procedure open / close chuck
Remove the tool in the chuck.

Insert the 3mm test pin.
During servicing work in the inside of

the machine there is the risk of injury
from the tool in the spindle!
Before any servicing in the inside of the
machine, the tool in the spindle must be
replaced by the test pin!

Service Manual Ceramill Motion2 Replacing the spindle
11. Replacing the spindle

Remove the tool from the spindle before
beginning the procedure.
Procedure open / close chuck

the housing!

11.1 Disassembly of the spindle

Disconnect the 9-pol Sub-D plug X19 of the
spindle control wire from the control system.
To detach the spindle control wire, remove the
sheath on the cable bundle.
Carefully cut through the cable ties on the two
compressed air hoses using side cutters.
It is essential to avoid damage to the

compressed air hoses!

Push in the retainer rings of the quick-release

coupling and remove the two compressed air
hoses.
Pull the centring rubber O-rings over the spindle

cover.
Ensure that all the rubber O-rings are

on the spindle cover.

Remove the protective cap of the spindle in the

inside of the machine.
Remove the two retention screws of the spindle
cover [1].
Carefully remove the spindle cover from the
spindle holder.
Loosen the two screws of the spindle clamp [2].

Pull the spindle carefully towards the back out of
the spindle holder.
Enter the serial numbers of the old and new

spindle in the service log.
The number is at the back of the spindle.

11.2 Assembly of the spindle
Check the condition of the two O-ring seals on the

spindle clamp and replace them, if necessary [3].
Lightly lubricate the two O-rings to facilitate
assembly of the spindle.
During assembly of the new spindle, align the
electrical connection of the spindle to approx. 9
o’clock and slide the spindle as far as it will go into
the spindle holder [4].
Tighten the screws of the spindle clamp using a
torque of 2.7 Nm.
Connect the two compressed air hoses to the
spindle.
White hose (back) – air supply for opening and
closing the chuck
Green hose (front)
- sealing air for discharging from the spindle
Push the compressed air hose firmly into the
quick-release coupling until there is clearly
perceptible resistance.
Slide the spindle cover over the spindle again [5].
Press the bellows at the side of the spindle cover
towards the back [6].
The O-rings on the back are pushed onto the
spindle holder from the spindle cover as a result.
Fit the spindle protection cap.
Re-secure the cable ties, which were removed
beforehand, and replace the sheath on the cable
bundle.

11.3. Setting the sealing air
Generally, the sealing air of the new spindle does not

have to be set, as it has already been preset to the
correct level at the factory.
If setting is required, proceed as follows:
Close the sealing air valve by turning it in a

clockwise direction as far as it will go.
Open the valve by 4.5 turns.
The sealing air is now set to a flow rate of 40 litres per
minute.
Up to serial number AAB12345 the

valve is directly on the spindle [3]
From serial number AAB12346

onwards the valve is in front of the air
control valve on the base of the
machine [4]

Service Manual Ceramill Motion2 Replacing the bellows
12. Replacing the bellows
12.1. Disassembly of the bellows
Procedure: move to the bellows replacement

position

the housing!
Remove the blank holder from the angle bracket.

Remove the 12 retention screws around the
outside of the bellows [1].
Remove both the screws on the spindle cover [2].
Carefully remove the spindle cover from the
spindle holder.
12.2. Assembly of the bellows
Remove the transport safety devices on the new

bellows [3].
Lubricate the O-ring seals on the
spindle holder [4].
Take great care with the joint of the two

plates when handling the bellows!
Do not bend the bellows in this area!
The rubber bellows could tear in this
area.
Ensure that the O-rings are on the

aluminium ring, as shown in the
photograph!
The bellows can now simply be fitted
into the machine!

Service Manual Ceramill Motion2 Replacing the bellows
Place the bellows on the spindle and slide the

spindle cover as far as it will go on the spindle
holder.
Ensure that the bellows are correctly

aligned!
The indicator mark must be on the right
of the bellows [5].
Carefully press the spindle cover on as far as it

will go [6].
The spindle cover should be flush with

the spindle holder.
Secure the spindle cover to the spindle holder.
Press the bellows at the side of the spindle cover

towards the back.
The O-rings on the back are pushed onto the
spindle holder from the spindle cover as a result.
Secure the bellows in the inside of the machine
using the new screws supplied.
Spray the bellows and O-rings on the bellows

thinly with silicone spray.

Service Manual Ceramill Motion2 Replacing the air control valve
13. Replacing the air control

valve

the housing!
Disassembly of the left side panel

Remove the two retention screws on the air
control valve.
Make reference marks on the supply

hoses to the air control valve to
facilitate assembly later!
Disconnect all connections to the air control valve.

Service Manual Ceramill Motion2 Checking the air control valve
14. Checking the air control

valve
The air control valve is intended to ensure that the
machine only operates from a minimum required
pressure of 5 bar.
If the pressure is too low, it can result in damage to
the spindle.
The setting of the air control valve can be checked

and adjusted in the following way:
Disassembly of the left side panel

Connect the pressure reducer [1] between the
compressed air filter and compressed air inlet of
the Motion
Connect the compressed air and mains plug and
switch on the machine.
Pull the flow control screw on the pressure
reducer out slightly and set the pressure to
0.5 MPa, which corresponds to a pressure
of 5 bar.
The air control valve must switch at a
pressure between 4.8 bar and 5.2 bar.
When the air control valve is switched
the red control LED on the air control
valve lights up.
If the control LED does not light up, the
air control valve must be adjusted.
Until the serial number XXXXXX the air

control valve must be removed for
adjusting to create access to the
adjustment screw!
From serial number AAB12346

onwards there is a cut-out section to
the side on the base of the machine
next to the air control valve to allow
access to the setting screw!

Service Manual Ceramill Motion2 Checking the air control valve
Turn the setting screw carefully to the left or right

until the red control LED lights up.
The air control valve has been preset

ex factory to a switching point of 5.0
bar.
The setting screw is covered by a
sticker.
Remove the sticker for readjusting the
switching point!
Gradually reduce the pressure on the pressure

reducer.
The control LED of the air control valve

must go out below a pressure of 4.8
bar!
Gradually increase the pressure on the pressure

reducer again.
The air control valve must switch and

the control LED should light up from a
pressure of 5.0 bar!

Service Manual Ceramill Motion2 Replacing the solenoid valve
15. Replacing the solenoid

valve

the housing!
Disassembly of the side panel

Remove the two retention screws on the solenoid
valve.
Make reference marks on the wires to

the solenoid valve to facilitate assembly
later!
Disconnect all connections to the solenoid valve.

Service Manual Ceramill Motion2 Replacing the length measurement unit
16. Replacing the length

measurement unit
16.1. Disassembly of the length

measurement unit
Inserting the test pin

the housing!


Disassembly of the housing
Disconnect the 9-pol Sub-D plug X19 from the
control system.
Cut through all relevant cable ties of the tool
length measurement unit wire [1].
Remove the 2 screws [2] and pull the tool length
measurement unit downwards out of the machine.
It is essential to reuse the sealing

rubber when assembling the new
length measurement unit!
16.2. Assembly of the length

measurement unit
Complete assembling the whole machine for

setting the machine parameters.
Setting the machine parameters

Service Manual Ceramill Motion2 Replacing the A-axis rotary table
17. Replacing the A-axis rotary

table
17.1. Disassembly of the rotary table

Procedure: Move to blank holder replacement
position

the housing!


Disconnect the plug X5E, X5M and X5R of the
rotary table from the control system.
Carefully turn the angle bracket manually towards
the front to create access to the retention screws
of the cover.
Remove the cover on the angle bracket.
Remove the mounting of the blank holder.
Insert an M4 screw in the stopper of the B-axis
and pull on the screw to remove the stopper from
the rotary table.
Take care not to damage the sealing

ring!
Underlay the pliers [1] !
Remove the two screws on the underside of the

angle bracket [2].
Remove the 4 retention screws
of the rotary table [3].

Service Manual Ceramill Motion2 Replacing the A-axis rotary table
Cut through the cable ties [4] and disconnect the

plug connections.
Carefully remove the rotary table from the angle
bracket.
Take care with the wires remaining on

the rotary table when removing it!
Enter the serial numbers of the old and new rotary

table in the service log.
17.2. Assembly of the rotary table
Insert the rotary table in the angle bracket and

connect all the wires.
Thread the wire on the rotary table through the
wire channel in the bracket.
Fit the mounting of the blank holder.
The mounting centres the rotary table

in the angle bracket.
Insert the two bottom screws [5] and only tighten

the screws slightly.
Tighten the 4 screws on the rotary table using a
torque of 2.7 Nm.
Then also tighten the two bottom screws.
Attach the cable ties in the middle of the angle
bracket.
Fit the cover on the angle bracket.
Ensure that the sealing surfaces on the

cover and angle bracket [7] are clean!
Press the stopper into the B-axis rotary table

again.
Connect the wire of the rotary table to the control
system.
Alignment of the A-axis

Service Manual Ceramill Motion2 Replacing the B-axis rotary table
18. Replacing the B-axis rotary

table
18.1 Disassembly of the rotary table

the housing!

Disconnect the plug X4E, X4M and X4R of the
rotary table from the control system.
Cut through all relevant cable ties of the rotary
table wire [1].
the rotary table.

ring!
Underlay the pliers [2] !
Remove the 4 screws on the angle bracket and

take the bracket out of the interior of the machine.
Remove the 4 retention screws of the rotary table
and remove the rotary table from the housing.
Enter the serial numbers of the old and new rotary
table in the service log.

Service Manual Ceramill Motion2 Replacing the B-axis rotary table
18.2 Assembly of the rotary table
Clean the underside of the new rotary table and

the support surface on the inside of the machine.
Place the rotary table on the inside of the machine
and retain it in position loosely with screws.
Carefully place the measuring shaft from below on
the rotary table and secure it in position using
4 screws.
The measuring shaft centres the rotary

table to the interior of the machine.
Tighten the screws of the rotary table using a

torque of 2.7 Nm.
Alignment of the B-axis


Service Manual Ceramill Motion2 Replacing the tool sensor
19. Replacing the tool sensor
19.1 Disassembly of the tool sensor
Procedure: Controlling axes

Move with the A-axis to an angle of -34.5
Tool T1 is above the tool sensor.

This position is needed for the
adjustment of the sensor.
Loosen the retention screws of the sensor on the

angle bracket [1].

the housing!


Disconnect the plug X16 of the tool sensor from
the control system.
Cut through all relevant cable ties of the tool
measurement unit wire.
Carefully turn the angle bracket manually towards
the front to create access to the retention screws
of the cover.
Remove the cover on the angle bracket.
the rotary table.

ring!
Underlay the pliers!

Service Manual Ceramill Motion2 Replacing the tool sensor
Cut through the cable ties on the A-axis rotary

table in the angle bracket [3].
Remove the tool sensor.
Ensure that the sealing O-ring remains

in the locating hole! [4]
19.2 Assembly of the tool sensor
Insert the sensor in the location hole and secure

carefully in position.
The distance between the sensor and

instrument shaft should be
0.2 - 0.3mm [5].
Fix the sensor in the correct position by lightly

tightening the clamping screw [6].
The sensor should not be clamped too

tightly.
Thread the wire of the sensor through the wire

channel in the bracket.
Attach the cable ties in the middle of the angle
bracket.
Put the cover on the angle bracket.
Ensure that the sealing surfaces on the

cover and angle bracket are clean!
Press the stopper into the B-axis rotary table

again.
Connect the wire of the rotary table to the control
system.

Service Manual Ceramill Motion2 Replacing the encoder
20. Replacing the encoder
20.1 Disassembly of the encoder

the housing!

Depending on the axis and encoder, different

methods of assembly and disassembly are
required.
Replacement of an easily accessible encoder is
described in this section.
Disconnect the encoder wire.

Unscrew the encoder cover.
Remove the encoder reader.
The encoder wheel must not be kinked!

Handle the encoder wheel carefully!
Unscrew the encoder wheel.
20.1 Assembly of the encoder
When assembling the encoder reader,

ensure that the encoder wheel runs in
the centre of the reader!
Install the encoder wheel in the centre of the

reader using a clamping screw.
The encoder wheel must not be kinked

or contaminated!
Handle the encoder wheel carefully!

Service Manual Ceramill Motion2 Replacing the 3-axis module
21. Replacing the 3-axis

module
21.1. Disassembly of the 3-axis

module

the housing!


Replacing the spindle
Disconnect all plug of the 3-axis module from the

control system.
X1E, X1M, X1R, X2E, X2M, X2R, X3E, X3M
and X3R,
Remove all the connections to the back connector
panel.
Make reference marks on the

connections to the back connector
panel to facilitate assembly later!
Remove the two retention screws of the back

connector panel.
Cut through the cable ties of the 3-axis system
wire.
Loosen all the plug connections to the 3-axis
module.

The 3-axis module is secured to the base profile with

a total of 6 screws.
These screws are under the bellows of the control

systems, which are secured using a Velcro fastening.
Loosen the Velcro fastener of the front bellows.

Remove the screws of the 3-axis module.
The 3-axis module must be moved

manually to gain access to all the
screws!
Pull the 3-axis module towards the back out of the

machine.
Enter the serial numbers of the old and new 3-
axis module in the service log. The number is on
the left of the 3-axis module.
21.2. Assembly of the 3-axis module
Remove all the transport safety devices from the

3-axis module.
Cut of the excess ends of the cable ties.
Connect the plug connectors to the encoder.
Place the 3-axis module on the machine
baseplate and initially secure it loosely in position
using the 6 screws.
Slide the 3-axis module forward and to the left as
far as it will go.
Tighten the 6 screws using a torque of 4.6 Nm.
Fit the back switch mounting plate to the base
plate.
Attach all connections to the switch mounting
plate.

21.3 Disassembly of the angle bracket
Disconnect all plug of the angle bracket from the

control system.
X5E, X5M, X5R and X16
Cut through all relevant cable ties of the rotary
table.

the rotary table.

ring!
Underlay the pliers [3]!
Remove the 4 screws on the angle bracket and

remove the angle bracket from the inside of the
machine.
Assembly of the spindle

Alignment of the B-axis

Service Manual Ceramill Motion2 Alignment of the B-axis
22. Alignment of the B-axis
22.1. Preparation for alignment
Connect the switch mounting plate temporarily to

the machine.
Connect the machine to the compressed air and
electricity supply.
Connect the machine to the PC
Procedure: Activating operation with the door
open
Perform a reference run
It is essential that the reference run is

completed BEFORE the assembly of
other components.
After assembly of other components it
could result in collisions and
consequently damage to the machine!
22.2. Axis alignment
Carefully place the measuring shaft from below on

the rotary table and secure it in position using 4
screws.
Ensure clean contact surfaces
Secure the dial gauge mounting on the spindle.

Insert the lever gauge in the location hole and
secure it using a clamping screw.
Align the lever gauge for moving the measuring
shaft to the front.
Move the measuring shaft to the front within the
measuring area. Find the highest point and set the
dial of the gauge carefully to 0.
Determine the deviation.
The maximum permissible tolerance is

+/- 0.3 mm.
Deviations from this value must be
corrected.

Shim the B-axis rotary table according to the

measured deviation.
shaft sideways.
Move the measuring shaft sideways within the
measuring area. Find the highest point and set the
dial of the gauge carefully to 0.
Determine the deviation.

+/- 0.2 mm.
corrected.
Shim the B-axis rotary table according to the

measured deviation.
The measuring shaft must be moved to

the front and side again after shimming!
It should be readjusted, if necessary!
If the measured deviation is within the tolerance

limits, the B-axis screws must each be crosswise
tightened using a torque of 4.7 Nm.
Remove the lever gauge from the holder.
It is essential that the gauge is removed

before assembly to prevent damage!
Remove the measuring shaft from the machine.

22.3. Pre-alignment of the angle

bracket
Perform a reference run
Before further assembly, switch off the

machine and remove the mains plug!
Clean the contact surfaces on the angle bracket

and B-axis.
Feed the wires of the angle bracket through the
channel in the B-axis.
Lubricate the sealing ring on the B-axis [1].
Place the angle bracket in position and secure
using 4 screws.
Press the stopper in the B-axis rotary table again.
Connect the plugs X5E, X5M, X5R and X16 to the
control system.
Connect the mains plug and switch on the machine.

Open Machine parameters in the Settings menu bar.
Tick A-axis available under the General tab.
Confirm the selection with Apply

Remove the mounting of the blank holder.

Place the measuring shaft carefully from the side
on the A-axis rotary table and secure it using 4
screws.
Remove the protective cap of the spindle.

Place the angle gauge with the long arm on the
measuring shaft and place the short arm on the
left next to the spindle.
Caution!
Reduce the feed rate for moving the
axes to 10 to 20%!

Carefully move the spindle forward using the Z-
axis to obtain as large a support surface as
possible of the short arm on the spindle.
Move the spindle carefully to the left using the X-
axis until there is almost contact with the angle
gauge.
Using the B-axis rotate the angle bracket with the
measuring shaft and the angle gauge in position
until the angle gauge is parallel with the spindle.
Move the axes carefully!

The angle gauge and spindle should
not collide with one another!
Remove the angle gauge from the machine.

Return the spindle to the rearmost position using
the Z-axis.
Spindle blocking aid
Fit the protective cap of the spindle.

Service Manual Ceramill Motion2 Angle adjustment of the B-axis
23. Spindle blocking aid
The spindle blocking aid is required to

prevent rotation of the spindle. This
allows alignment of the dial gauge and
lever gauge!
Unscrew the protective cap of the spindle and

insert the spindle blocking aid [1].
Replace the protective cap of the spindle.
Press the protective cap firmly against the spindle
and retighten the screws.
It is essential to remove the spindle

blocking aid after setting is complete!
Otherwise the spindle will be damaged
during normal operation!

24. Angle adjustment of the

B-axis
24.1. Preparation for angle adjustment
Connect the switch mounting plate temporarily to

the machine.
Connect the machine to the compressed air and
electricity supply.
Connect the machine to the PC
Procedure: Activating operation with the door
open
Spindle blocking aid
24.2. Setting the angle
Place the measuring shaft carefully from the side

on the A-axis rotary table and secure it using
4 screws.
Procedure: Opening and closing the chuck

Place the lever gauge in the opened chuck with
the dial facing upwards and insert it fully.
Close the chuck.
Procedure: Controlling the axes
shaft to the back.
Use the mirror from the service case as

an aid!
Align the lever gauge so that only the

ball tip is in contact with the measuring
shaft!
Move the measuring shaft to the back within the

measuring area vertically up and down. Find the
highest point and set the dial of the gauge
carefully to 0.

Move the measuring shaft from left to right and

determine the deviation on the dial.
Important!
The measuring shaft must always be
moved from left to right!
Adjust the B-axis.
Caution!
It is essential to select 0.01 as the
“defined path” in order to move the B-
axis.
Example:
If the dial gauge indicates 0.10 mm, the
B-axis must be adjusted until the value
0.05 mm is displayed!
After adjustment of the B-axis, move the

measuring shaft and adjust, if necessary, until the
deviation is within the tolerance limits.

+/- 0.01 mm.
corrected.
Note the adjustment value of the B-axis given in the programme under Position.

The value noted should be added to or subtracted from the current value of the B-axis in the programme under
Settings > Machine parameters.
Rule:
If the adjustment value is positive, it must be subtracted from the value to be corrected.
If the adjustment value is negative, it must be added to the value to be corrected.
Example:
Adjustment value +0.93°, the value to be corrected in the machine parameters -13.953°
According to the rule applied the result is: -13.953°-0.93° = -14.882°
Enter the corrected value in the programme.

Click on Apply.
Remove the dial gauge mounting and dial gauge from the machine.
Perform a reference run of the machine

After the reference run, fit the lever gauge to the

spindle again.
shaft to the back.
Move the measuring shaft again and adjust, if
necessary, until the deviation is within the
tolerance limits.

+/- 0.01 mm.
corrected.
After successful setting, remove the lever gauge

from the spindle.
Procedure: Move to the reference position

Service Manual Ceramill Motion2 Adjustment of a horizontally inclined position of the A-axis
25. Adjustment of a
horizontally inclined position of
the A-axis
A horizontally inclined position of the A-

axis is adjusted purely mathematically
by the NC programme.

Place the lever gauge with the display facing
upwards in the opened chuck and insert it fully.
Close the chuck.
Align the lever guide underneath for moving the
measuring shaft.

an aid!
Align the dial gauge so that only the

ball tip is in contact with the measuring
shaft!
Move the measuring shaft horizontally back and

forward to the bottom within the measuring area.
Find the highest point and set the dial of the
gauge carefully to 0.
Move a defined 75 mm with the X-axis to the right
and determine the deviation on the dial.
Note the deviation obtained from the dial of the
lever gauge.

+/- 0.01 mm.
corrected.
Move the defined 75 mm again to the left with the

X-axis to the starting point.

Service Manual Ceramill Motion2 Adjustment of a horizontally inclined position of the A-axis
The noted value must be entered in the field under ΔY in the programme under Settings > Machine
parameters > A-axis.
Example: A deviation of 0.04 displayed on the dial gauge corresponds to a ΔY of 0.04 mm.
Click on Apply
Place a tick in the programme next to the field

Correct oblique position.
Move the defined 75 mm with the X-axis to the
right and determine the deviation on the dial.

+/- 0.01 mm.
Move the defined 75 mm again to the left with the

X-axis to the starting point.

Service Manual Ceramill Motion2 Spindle blocking aid
Deactivate the tick next to the field Correct

oblique position.
Enter the value 0.01 mm again in the programme
as the defined path.
Remove the lever gauge from the spindle.
Remove the measuring shaft from the A-axis
rotary table.
Lubricate the sealing ring on the A-axis [1].
Fit the mounting of the blank holder on the A-axis

rotary table.
The pin in the mounting of the blank

holder must point towards the front!
Complete assembling the entire machine for

setting the machine parameters.
Setting the machine parameters

Service Manual Ceramill Motion2 Ceramill Motion service programme
26. Ceramill Motion service programme
26.1. Start of the service programme
The service programme can be used to determine and set the machine parameters.
The service programme is a sub-programme of the Ceramill Motion software and is started from there.
Re-check the status of the machine to ensure that it has been assembled correctly before starting the service
programme.
Connect the machine to the computer via a USB or network cable.
Connect the machine to the compressed air and electricity supply
Switch on the Ceramill Motion.
Start the Ceramill Motion software on the computer.

The password entry box for the service programme is accessed by double clicking on the Ceramill Motion
logo.
Enter the password.
The password consists of day + month + year.
Example:
20.01.2011 = 20 + 01 + 2011 = 2032
26.2. Ceramill Motion service programme
The Ceramill Motion service programme contains the additional functions Referencing [1] and Manual [2],
which are required for setting the machine.
In addition, the Machine parameters can now also be called up under the menu item Settings.

26.3. Activating operation with door open
It is practical to activate the function Allow motion with protection shield open for the duration of the service.
Open Machine parameters in the Settings menu bar.

Tick the box at Allow motion with protection shield open under the General tab.
Click on Apply at the bottom right.
Activating the Allow motion with protection shield open function allows access to the inside of
the machine.
There is the risk of becoming jammed when moving the machine.
This setting automatically resets each time the machine is switched off.
The function must be reactivated, if necessary!

Service Manual Ceramill Motion2 Ceramill Motion service programme procedures
27. Ceramill Motion service programme procedures

The procedures described in this section recur repeatedly during determination of the machine parameters and
are described here in the form of an example.
27.1. Moving to the reference position
The machine should be moved into the reference position before any repair work on the Ceramill Motion, as this
position allows the best accessibility to the individual components.
Click on the Homing button and start the reference run by clicking the Move to home position button.
Wait until this is fully completed.
26.2. Controlling the axes
All the axes can be controlled either manually from the PC or directly using the two control keys on the Ceramill
Motion.
Click on the Manual button.
The axes are controlled using the X, Y, Z, A, B control keys and pre-selection of the speed.

No collision checks are carried out by the programme during movement of the axes when operating
the machine from the service programme!
2 different travel path modes are available for moving the axes:
 Continuous procedure
If this mode is selected, the axes are moved at the preselected speed as long as the button of the respective
axis is pressed with the mouse.
 Defined path
If this mode is selected, the axes are moved using the predefined travel parameter.

By activating the two control keys on the Ceramill Motion, the axes can be controlled using these keys according
to the selected travel path mode and movement speed.
Click on the button to activate both control keys.

27.3. Opening and closing the chuck
Click on the Manual button.
Click on the respective chuck symbol to open or close the chuck. The chuck changes colour depending on
whether the chuck is open or closed.
If the chuck is closed without a tool inserted, it can result in deformation of the chuck.
Never close the chuck without a tool inserted.
27.4. Moving to the blank holder replacement position
With the door closed, press the A control key for a minimum of 3 seconds.
The blank holder moves to the replacement position.
27.4. Calibration settings aid programme
The Calibration settings aid programme enables automatic movement of the different measurement positions for
determination of the machine parameters.
The programme is opened as follows:
Click on the Manual button and then on the Setup/Calibration button.

Click on Open file and select the Calibration-settings – Motion2.sc file.
The following window is then opened.
By clicking the green arrow to the left of the required measuring position, the programme automatically moves the
axis to the saved position.
No collision checks are carried out by the programme during movement of the axes when operating
the machine from the service programme!

Service Manual Ceramill Motion2 Determining the machine parameters
28. Determining the machine parameters

The machine parameters must always be redetermined if components, which affect the machine parameters, are
replaced or readjusted.
This includes the following components:
 3-axis module
 Blank holder
 Rotary table
 Tool detection unit
 Tool length measurement unit
28.1. A-axis zero point
Procedure: Move to blank holder replacement

position
Fit the blank holder and tighten the screws using a
torque of 4 Nm.
Remove the protective cap of the spindle.
Place the angle gauge with the long arm on the
blank holder and place the short arm above the
spindle.
Caution!
Reduce the feed rate for moving the
axes to 10 to 20%!

Carefully move the spindle forward using the Z-
axis to obtain as large a support surface as
possible of the short arm on the spindle.
Move the spindle carefully upwards using the Y-
axis until there is almost contact with the angle
gauge.
Using the A-axis, rotate the blank holder with the
angle gauge in position until the angle gauge is
parallel with the spindle.
Move the axes carefully!

The angle gauge and spindle should
not collide with one another!

Remove the angle gauge from the machine.

Return the spindle to the rearmost position using
the Z-axis.
Fit the spindle blocking aid
Fit the protective cap on the spindle.
Place the dial gauge with the display facing right
in the open chuck and insert it fully.
Procedure: Calibration settings

Move to the measuring point A-axis M1.
Turn the scale ring of the dial gauge to zero.

an aid!

Move to the measuring point A-axis M2.
Determine the difference in value shown.

an aid!
Adjust the A-axis.
Caution!
“defined path” in order to move the A-
axis.
Example:
If the dial gauge indicates 0.10 mm on
the measuring point A-axis M2, the A-
axis must be adjusted until the value
0.05 mm is displayed!
Now turn the scale ring of the dial gauge at the

measuring point A-axis M2 to 0.
Move again to the measuring point A-axis M1.
The dial gauge should now show a

maximum deviation of +/- 0.01 mm!
If the value displayed is outside the

permitted tolerance, the procedure
must be repeated!

Note the adjustment value of the A-axis given in the programme under Position.
Add or subtract the noted value in the programme under Settings > Machine parameters > A-axis to or from
the current value in the programme.
Rule:
If the adjustment value is positive, it must be subtracted from the value to be corrected.
If the adjustment value is negative, it must be added to the value to be corrected.
Example:
Adjustment value - 0.02°, the value to be corrected in the machine parameters - 0.240°
According to the rule applied the result is: - 0.240° + 0.02° = - 0.220°

Enter the corrected value in the programme.

Click on Apply.
Remove the dial gauge mounting and dial gauge
from the machine.
After the reference run, fit the dial gauge mounting
and dial gauge again to the spindle as a check.
Move to the measuring points A-axis M1 and
A-axis M2 and compare the measurements.
If there is a deviation, it should be adjusted
according to the steps described above.

+/- 0.01 mm.
corrected.
After successful setting, remove the dial gauge

mounting and dial gauge from the spindle.
Remove the spindle blocking aid.
It is essential to remove the spindle

blocking aid after setting is complete!
Otherwise the spindle will be damaged
during normal operation!

28.2. X/Y zero point

Move to the measuring point X/Y zero point M1.
Place the test sleeve on the projecting test pin

and slide it carefully into the test aperture.
The test sleeve must be able to slide
into the test aperture without any
resistance!
If there is resistance, the position of the
test pin must be adjusted.
If necessary, adjust the X-axis and the Y-axis.

Procedure: Controlling the axes.
Caution!
“defined path” in order to move the
axis.

After successful adjustment, note the value of the X-axis and Y-axis for the measuring point X/Y zero point
M1 given in the programme under Position.
Move to the measuring point X/Y zero point M2.
Place the test sleeve on the projecting test pin

and slide it carefully into the test aperture.
The test sleeve must be able to slide
into the test aperture without any
resistance!
If there is resistance, the position of the
test pin must be adjusted.
If necessary, adjust the X-axis and the Y-axis.

Caution!
“defined path” in order to move the
axis.

After successful adjustment, note the value of the X-axis and Y-axis for the measuring point X/Y zero point
M2 given in the programme under Position.
The blank zero point = X/Y zero point can be calculated from these X/Y values determined for the two measuring
points X/Y zero point MI and X/Y zero point M2.
X zero point M1+X zero point M2 X zero point M1+X zero point M2
Rule: X= Y=
2 2
(−89.66)+(−89.70) −179.36
X= = = −89.680
2 2
Example:
(−29.95)+(−99.90) −129.85
Y= = = −64.925
2 2

Enter the calculated values in the programme under

Settings > Machine parameters > Positions > Blank zero point and accept the value with Apply.

Remove the test pin

28.3. Tool 1 - Tool check
Place the test pin in the

tool compartment T1.

Move to the measuring point Tool check M1.
Check the distance between the test pin shank

and the tool sensor using the correct thickness of
spacer foil.
To ensure that the tool can be correctly

detected the distance must be between
0.2 mm and 0.3 mm.
If there is any deviation, the position
must be adjusted!
If there is deviation, loosen the clamping screw of

the sensor on the back of the angle bracket.

an aid!

Move the sensor to the correct position with the

aid of the correct thickness of spacer foil.
Ensure that the sensor is not pushed

too far into the housing!
Fix the sensor in the correct position by lightly

tightening the clamping screw.
The sensor should not be clamped too

tightly.
Check the correct position of the tool sensor in the programme under
Settings > Machine parameters > Positions > Tool 1 – Tool check.
If the tool sensor has been set correctly, it is indicated by the blue highlighted Sensor active
control button.
If the control button is not highlighted blue, the tool cannot be detected and the position of the tool
sensor must be readjusted!

Check the position of the test pin shank using the

tool sensor.
The test pin shank must be as central

as possible over the sensor.
If there is an angular deviation, it must
be corrected!
If there is an angular deviation, rotate the A-axis

until the shank of the test pin is in the centre over
the tool sensor.
Click on Settings > Machine parameters > Positions > Tool 1 – Tool check.
Click on button =A in this window.
The adjusted angle value of the A-axis is shown in the mask as a result of this action.
Accept the value shown by clicking the Apply button.

28.4. Tool 1
Tool pick-up position
The machine parameter position Tool 1

M1 is the position that the spindle
moves to in order to pick up a tool with
the chuck in the spindle.
If the position has been set optimally,
the tool will be picked up tension free!
Place the test pin in the tool compartment T1 and

push it as far as it will go towards the centre of the
A-axes.

Click on the measuring point Tool 1 M1
Move the spindle with the chuck carefully step by

step in the Z direction towards the shank of the
test pin. Adjust the position of the spindle in the
X/Y direction, so that the chuck can move onto the
shank.
Move gradually to the shank.
Continually check during the procedure

whether the test pin can still be moved
easily back and forward in the tool
holder.
If not, the position of the spindle must
be adjusted in the X/Y direction!

Repeat this procedure until the chuck is almost at

the tool holder.
The test pin must still be able to be

moved easily back and forward in this
end position!
Move a defined 1 mm back using the Z-axis.

Push the test pin fully forward manually as far as it
will go.
Close the chuck.
In the programme click on Settings > Machine parameters > Positions.

Select Tool 1 and click on the =X, =Y, =Z buttons.

The values determined are shown in the mask as a result of this action.
Accept the values shown by clicking on the Apply button.

Move a defined 5 mm to the right using the X-axis.
After moving, reset the value of 0.5 mm to 0.1 mm.

28.5. Tool length measurement

Move to the measuring point Tool length M1.
In the programme click on Settings > Machine parameters > Positions

>Tool length measurement M1.
Move the Z-axis forward gradually until the control button
Switching threshold reached is highlighted blue.

The Sensor position should be at approx. 210 incr.
After reaching the switching threshold, move the Z-axis forward by another 2 to 3 incr.
Example: Switching threshold reached at 212 incr.

Move further to 215 incr.

Select Tool length measurement and click on the =X, =Y, =Z buttons.
The values determined are shown in the mask as a result of this action!
Accept the values shown by clicking on the Apply button.

28.6. Blank zero point

Move to the measuring point Z-axis zero point.
Place a 0.1 mm thick spacer foil between the test

pin and blank holder.
Move the Z-axis forward gradually until the foil is
just held in position on the blank holder by the test
pin.
Procedure: Controlling the axes.
Carefully find the correct position step

by step!
Excessive pressure can cause
damage!


Select Blank zero point and click on the =Z button.
The Z value determined is shown in the mask as a result of this action.
The Z value now shown must be adjusted by the fixed correction value of 7 mm!
Rule:
7 mm must be subtracted from the Z value shown!
Example:
Z value shown -72.867 mm minus 7 mm = - 79.867 mm
Enter the calculated Z value in the mask.

Accept the adjusted value by clicking the Apply button.

28.7. Tool change function check
Remove the test pin from the chuck.

Removing the test pin
Place the test pin in the T1 compartment.
Click on the 1 button in tool selection under Tool.
The test pin on the tool compartment

T1 is automatically picked up by the
chuck.
Using a mirror, ensure that the
procedure functions perfectly!
Click on the 0 button once the function has been

successfully completed.
The test pin is automatically replaced in

its T1 compartment.
Place the test pin in the T6 tool compartment and

check the function using the same procedure as
for the T1 compartment.
Remove the test pin from the tool holder.

28.8. Deactivating operation with open door
Click on Settings > Machine parameters > General.

Remove the tick from Allow operation with open safety guard.
Accept deactivation by clicking the Apply button.

Service Manual Ceramill Motion2 Milling test blocks
29. Milling test blocks

Place the Ceramill Roto Motion 2.5 mm cutter in the tool holder at T1
and the Ceramill Roto Motion 1.0 mm cutter in the tool holder at T2.
Place a ZI 71 test blank in the blank holder and secure the blank firmly in position using the screws.
29.1. Blank configuration
There are programmes in the software for milling a total of 8 test blocks.
The test blocks are arranged as follows in the test blank.
29.2. Loading the test block programme and milling
Click on the folder symbol in the menu list.

Click on Test programmes (Ø 2.5 mm) and then select 2 test block programmes from the Motion 2
programmes.
Important!
2 test programmes must always be selected and milled!
Test blocks 1 + 3 or Test blocks 4 + 6
Programme for Motion2 Cutter Ø Test block No.
After selection, click on Transfer data

Once the transfer has been completed, click on the start button.
The machine begins milling the test blocks.
Once milling has been completed, manually twist the respective test blocks out of the test blank.

29.3. Measurement of the test blocks + adjustment of the machine parameters
Measure the test blocks.

Open the Excel table and enter the measured values of the test blocks in the relevant fields (see marking).
When entering the values, ensure that the measurements of the test blocks 1 and 3 or test blocks 4
and 6 are entered in the respective table!

In the Ceramill Motion programme click on Settings > Machine parameters > Positions.
Select Blank zero point in positions.
Note the given values for X, Y, and Z
Click on the B-axis tab and note the Position on the reference sensor value given.

Enter the noted value in the Excel table in the Parameter before adjustment column.
The programme then automatically calculates the new machine parameters from the
measurements and machine parameters entered.
The new machine parameters are shown under Parameter adjustment 1
If X 0.000 is given as a value, this value does not have to be adjusted in the machine parameters.

In the Ceramill Motion programme click on Settings > Machine parameters > Positions.
Select Blank zero point in positions.
Transfer the calculated values from the Excel table and enter them at the respective axis.
Click on the B-axis tab and enter the calculated value from the Excel table.
Accept each of the values entered by clicking the Apply button.

Perform a reference run.

It is essential to move to the reference position to ensure that the altered machine parameters are
active for the next test block milling procedure!
Place a new ZI 71 test block in the blank holder and secure the blank firmly in position using the screws.
Re-mill the test blocks milled previously and measure the blocks.
If the value is outside the tolerance of 14+/- 0.05 mm, the parameters must be re-adjusted!
Enter the measured value again in the next column of the Excel programme.
The values of the machine parameter to be adjusted are automatically shown in the table
Parameter adjustment 2.
Transfer the calculated values again in the machine parameters.

It is essential to move to the reference position to ensure that the machine parameters are active!

29.3. Determining the test block offset situation
The front section of the block is milled first when milling the test blocks.
The A-axis is then rotated by 180° and the back section of the test block is milled.
An offset can occur from the front to the back section of the block due to axis deviations.
This can cause 2 different types of offset situations!
 Offset situation number above
The front section of the test block with

milled identification number ABOVE the
back section of the test block.
 Offset situation number below
The front section of the test block with

milled identification number BELOW
the back section of the test block.
Determine the offset situation for both milled test

blocks 1 + 3 and 4 + 6
29.4. Measuring the test block offset
First, measure the height of both test blocks in the

front section and note the value = A
The height will be approx. 10 mm.
Then measure the height of the test block in the

middle section and note the value = B
The front section overlaps the back

section in the middle section of the test
block.
The offset is calculated from the height
of the middle section!

Determine the difference in the heights A and B of the two test blocks.
Example:
Test block 3 height A = 9.98 mm

Test block 3 height B = 9.94 mm
Difference in height = A – B = 0.04 mm
In the programme place a tick at the respective field Offset situation above or Offset situation below and
enter the height difference obtained in the respective field of the table.
If one of the test blocks of a test block pair has an offset and the other does not, enter the same
value in the table for the two test blocks!
The programme then automatically calculates the new machine parameters from the
measurements and machine parameters entered.
The new machine parameters are shown under Parameter adjustment X.
If X 0.000 is given as a value, this value does not have to be adjusted in the machine parameters.
Transfer the calculated values again to the machine parameters.

It is essential to move to the reference position to ensure that the machine parameters are active!

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Service Manual Ceramill Motion2 Contents

Amann Girrbach AG Page 1 of 92

Amann Girrbach GmbH

Amann Girrbach America, Inc.

Subject to changes due to technical improvements!

Copyright by: © Amann Girrbach AG 2012

Amann Girrbach AG Page 2 of 92

2. Basic instructions ................................................................................................................ 8

3. Ceramill Motion2 parts overview ...................................................................................... 11

4. Disassembly of the side panels........................................................................................ 13

5. Disassembly of the side panel.......................................................................................... 14

6. Disassembly/assembly of the door .................................................................................. 15

7. Disassembly of the control system .................................................................................. 16

8. Disassembly/assembly of the switch mounting plate .................................................... 17

9. Disassembly of the housing ............................................................................................. 18

10. Inserting the test pin........................................................................................................ 19

11. Replacing the spindle ...................................................................................................... 20

12. Replacing the bellows ..................................................................................................... 25

13. Replacing the air control valve ....................................................................................... 27

14. Checking the air control valve ........................................................................................ 28

15. Replacing the solenoid valve .......................................................................................... 30

Amann Girrbach AG Page 3 of 92

16. Replacing the length measurement unit ........................................................................ 31

17. Replacing the A-axis rotary table ................................................................................... 32

18. Replacing the B-axis rotary table ................................................................................... 34

19. Replacing the tool sensor ............................................................................................... 36

20. Replacing the encoder .................................................................................................... 38

21. Replacing the 3-axis module .......................................................................................... 39

22. Alignment of the B-axis ................................................................................................... 42

23. Spindle blocking aid ........................................................................................................ 46

24. Angle adjustment of the B-axis ..................................................................................... 47

25. Adjustment of a horizontally inclined position of the A-axis ....................................... 51

26. Ceramill Motion service programme .............................................................................. 54

27. Ceramill Motion service programme procedures ......................................................... 57

Amann Girrbach AG Page 4 of 92

28. Determining the machine parameters ............................................................................ 62

29. Milling test blocks ............................................................................................................ 83

Amann Girrbach AG Page 5 of 92

1.1 About this manual

The layout of the instructions is as follows:

1.2 Qualification of the service personnel

1.3 Manufacturer service

Amann Girrbach GmbH

Amann Girrbach AG Page 6 of 92

DE Tel.: +49 7231 957-100

1.4 Returns to Amann Girrbach

Amann Girrbach AG Page 7 of 92

Other instructions are intended to facilitate repair of the Ceramill Motion 2.

2.1 Safety instructions of this manual and their significance

Remove the mains plug before opening

There is the risk of becoming jammed when moving the machine.

The components and measurement tools could be damaged if collisions occur.

Ensure that you are electrostatically

Amann Girrbach AG Page 8 of 92

This safety instruction indicates a

2.2 Other instructions