ZIMM ZA-25 User manual

Instruction manual
Installation – Operation – Maintenance – Inspection
ZIMM Actuator
ZA-25
to
ZA-200
2023
-10
0.6
EN

Translation of the original instruction manual
Publisher
ZIMM GmbH
Millennium Park 3
6890 Lustenau/Austria
Tel.: [phone]
Fax: [phone]
e-mail: inf[email protected]om
Internet: https://www.zimm.com
Author
ZIMM GmbH
Issue date
2023-10
Version
0.6
Copyright
© ZIMM GmbH
We reserve the right to make changes to technical aspects and content
Legal notices
The contents of this instruction manual must be kept confidential. It is
intended only for use by company personnel.
Reproduction or distribution and release of this instruction manual to
third parties is prohibited. Offenders are liable to pay damages.
The ZIMM GmbH accepts no liability for damages arising from
disregard of this instruction manual.

ZIMM Actuator
1 About this document
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Contents
1 About this document .......................................................................................................................5
1.1 Use of this instruction manual......................................................................................................5
1.2 Symbols and identifying marks....................................................................................................5
2 Safety.................................................................................................................................................6
2.1 Use for the intended purpose ......................................................................................................6
2.2 Duties of the operating company ................................................................................................6
3 Scope of supply................................................................................................................................7
4 Description of the product ..............................................................................................................7
4.1 Overview .........................................................................................................................................7
4.2 Rating plate ....................................................................................................................................8
4.3 Versions/variants ........................................................................................................................... 9
4.4 Grease nipple.............................................................................................................................. 10
5 Transport and storage ...................................................................................................................11
5.1 Transport...................................................................................................................................... 11
5.2 Storage......................................................................................................................................... 13
6 Installation.......................................................................................................................................14
6.1 Installing actuators and bevel gear drives............................................................................... 15
6.2 Fitting the couplings and connecting shafts............................................................................ 17
6.3 Fitting the motor.......................................................................................................................... 19
6.4 Connecting the electrical components .................................................................................... 20
6.5 Trial running................................................................................................................................. 22
6.6 Correcting the alignment ........................................................................................................... 23
6.7 Commissioning ........................................................................................................................... 24
6.8 Running-in phase ....................................................................................................................... 25
7 Operation and maintenance ......................................................................................................... 26
7.1 Inspection .................................................................................................................................... 26
7.2 Lubrication ................................................................................................................................... 27
7.3 Troubleshooting .......................................................................................................................... 34
8 Decommissioning and recommissioning ................................................................................... 36
9 Repair and replacement................................................................................................................ 36
10 Disposal.......................................................................................................................................... 36
11 Declaration of incorporation ........................................................................................................ 37
12 Appendix: Inspection certificate.................................................................................................. 38

1 About this document
ZIMM Actuator
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Further interesting information on lifting
systems and suitable components and
their design can be found in our
"screw jacks" catalog.

ZIMM Actuator
1 About this document
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1 About this document
1.1 Use of this instruction manual
This instruction manual forms part of the ZIMM Actuators.
Before using the equipment read the instruction manual carefully.
Keep the instruction manual safe throughout the working life of the
equipment.
Keep the instruction manual available to operating and maintenance
personnel at all times.
Pass the instruction manual to any subsequent owner or user of the
equipment.
Keep the instruction manual updated with any supplements issued
by the manufacturer.
1.2 Symbols and identifying marks
Symbol Meaning
DANGER
Hazards to personnel
Disregard will lead to death or serious injuries.
WARNING Hazards to personnel
Disregard may lead to death or serious injuries.
CAUTION Hazards to personnel
Disregard may lead to minor injuries.
CAUTION
Information for avoiding damage to property
NOTE Notes for understanding or
optimising working procedures
 Precondition to an operation
 Single step operation requirement
1. …
2. …
Multi-step operation requirement
Comply with the sequence
Tab. 1: Symbols and identifying marks

2 Safety
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2 Safety
The ZIMM Actuator has been produced to modern standards and
recognised safety regulations. Nevertheless hazards to life and limb of
the users or third parties, or risks of damage to the ZIMM Actuator and
other property may arise during use.
The ZIMM Actuator may be used only when it is in technicallygood
condition and in compliance with the instruction manual.
Have any defects rectified without delay.
Do not perform any unauthorised modifications to the ZIMM
Actuator.
Fit only original spare parts from ZIMM GmbH.
2.1 Use for the intended purpose
The ZIMM Actuator is suitable only for lifting, lowering, tilting and
advancing movements within the specified lifting capacity ranges.
Responsibility to ensure correct use lies with the user.
Screw jacks may be used only in the context and within the limits
specified in our catalogues and brochures.
To ensure compliance with the statutory limits for electromagnetic
compatibility, the ZIMM Actuator may be used only within industrial
applications as defined in EN 50 081-2.
Use for any purpose other than these intended purposes constitutes
improper use.
If in doubt regarding the application of the ZIMM Actuator, consult
ZIMM GmbH before proceeding.
2.2 Duties of the operating company
Ensure that the ZIMM Actuator is operated and maintained onlyin
compliance with this instruction manual and the rules and
regulations applicable in the country of use.
Ensure that the personnel
– responsible for operating the ZIMM Actuator are authorised,
– are trained and qualified for the respective work,
– have read and understood this instruction manual,
– know the applicable safety rules and
– wear personal safety equipment
(safety gloves, safety helmet and safety shoes).

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3 Scope of supply
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3 Scope of supply
The ZIMM Actuator is delivered in sufficiently secure packaging to
prevent possible damage in transit.
The scope of supply of the ZIMM Actuators includes the following parts:
• ZIMM Actuator
• This instruction manual
• Further parts as listed on the delivery note
4 Description of the product
4.1 Overview
Fig. 1: Overview ZIMM Actuator
A to F: Faces of the ZIMM Actuators.

4 Description of the product
ZIMM Actuator
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4.2 Rating plate
2
6
3
1 4
5
Fig. 2 Example of a rating plate
1 ZIMM contact data
2 Type designation
3 Maximum static load actuator
(spindle etc. not considered)
4 Rated speed
5 Serial number
6 Serial number as
Data Matrix Code

ZIMM Actuator
4 Description of the product
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4.3 Versions/variants
Variant
ZA-series,
(with Trapezoidal screw spindle
TR)
1 Mounting head
2 Thrust tube
3 Head nut
4 Cylinder tube
5 Housing, ZE series
6 Drive shaft
7 Lubrication of spindle and
anti-rotation lock
ZA-series,
(with Ball screw drive KGT)
1 Mounting head 5 Housing, ZE series
2 Thrust tube 6 Drive shaft
3 Head nut 7 Lubrication of spindle and
4 Cylinder tube anti-rotation lock
1
3
4
7
2
5
6
7
1
3
4
7
2
5
6
7

4 Description of the product
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4.4 Grease nipple
ZIMM Actuators have grease nipples that ensure easy and clean
lubrication of the screw drives and the anti-rotation lock.
HINWEIS

For optimal lubrication, use an automatic and controlled lubricator
(PLC-capable).

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5 Transport and storage
5.1 Transport
WARNING
Falling load!
Falling loads may lead to serious injuries.
Make sure that the lifting slings that are used are securely
attached and cannot slip.
Do not remain under a suspended load.
Wear personal safety equipment.
CAUTION
Heavy weight!
Injuries from parts weighing 25 kg and above.
Transport the heavy ZIMM Actuators (max. 25 kg perperson).
CAUTION
Damage to the ZIMM Actuator!
On receipt, check the packaging for signs of damage.
Do not let the ZIMM Actuator drop, and do not subject it toimpacts.
Use appropriate lifting gear as necessary.
Bending of the thrust tube or spindle!
Handle long and thin thrust tubes with particular care to avoid
damage.

5 Transport and storage
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ZIMM Actuator
Fig. 3: Examples for transporting the ZIMM Actuator
When lifting with a crane, attach the slings to the lifting points
provided.
When lifting the ZIMM Actuator for transport, spread the weightas
evenly as possible across all the lifting points.

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Securing for transport For secure attachment, insert ring bolts or ring nuts to the gearbox.
Fig. 4: Fit ring bolts (1) or ring nuts (not supplied)
5.2 Storage
CAUTION
Incorrect storage!
Damage due to corrosion.
Store only in enclosed and dry rooms.
Protected against soil moisture.
Do not store for more than a brief period in areas that although
roofed still allow free circulation of air from outside.
Perform commissioning not later than 1 year after delivery (the
dispatch from ZIMM is the relevant date).
For other storage conditions and storage times:
Consult ZIMM GmbH.

6 Installation
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6 Installation
CAUTION
Laceration, trapping and crushing hazards!
Switch off the entire system and secure it against switching on
again.
Allow only skilled and trained personnel to perform the work.
Do not remove the covers that are fitted.
Wear personal safety equipment.
Sharp edges!
Laceration hazard.
Wear safety gloves.
CAUTION
High forces are generated!
Material damage to the entire system and the ZIMM Actuator.
Ensure that the following installation conditions are satisfied:
– Limit switches are not overrun.
– For parallelism and angularity tolerances: see section 6.1,
page 15.
– Directions of rotation and movement are correct for all
components.
– Safety clearance between moving and fixed parts is
maintained.
Lack of self-locking!
Material damage to the entire system and the ZIMM Actuator due to
lack ofself-locking for spindles with ball screw drive KGT.
Spring pressure brake FDB or brake motor provided.
Make sure that the thrust tube does not reach the hard stop
during assembly.

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CAUTION
The system will run on!
Material damage to the entire system and the ZIMM Actuator due to
running on.
• The run-on travel may increase after the running-in phase.
If necessary provide a spring pressure brake FDB or brake motor.
NOTE
Additional hazards may arise during installation and operation of the
overall system.
Comply with regional regulations and take necessary measures
(such as risk assessment).
Document all additional hazards in the documentation for the
overall system.
6.1 Installing ZIMM Actuator and bevel gear drives
 Pay attention to the maximum permissible lateral load on the
mounting head of the ZIMM Actuator.
 Protect the thrust tube from damage and do not twist it with
force.
Fig. 5: Pay attention to the maximum lateral load on the mounting head.

6 Installation
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Fig. 6: Flatness, parallelism and angular accuracy
1. Set up the ZIMM Aktuator and ensure compliance with the installation
accuracy, and ensure straight alignment of the spindle attachment (e.g.
with precision machine spirit level).
2. Install the ZIMM Actuator with bolts, tighten the installation bolts.
3. Mount the screws for sizes 50 and 100 of the ZA series on the
elongated holes with washers (e.g. according to DIN 1441). Mount
the spindle head (see Fig. 9), fix the locking screws with screw
locking (e.g. Loctite) and mount the lock nut (up to size 100).
Fig. 7: Fix parts such as Fixing flange, Forked end, Pivot bearing end,
Rod end, after setting the position.

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Bevel gear drive The T version can be turned round to change the direction of rotation.
Fig. 8: T version (bevel gear drive)
Check the direction of rotation at installation.
6.2 Fitting the couplings and connecting shafts
 The ZIMM Actuator to be connected must have been fully installed.
 The bevel gear drives must be installed where appropriate.
CAUTION
Moving parts!
Injuries due to rotating parts.
Switch off the entire system and secure it against switching on
again.
1. Place the connecting shaft on the shaft extensions (ZIMM
Actuator or bevel gear drives). Check that the gearboxes are
correctlylevelled.
2. Secure the coupling half shells with attachment bolts tightened
tothe following torques:
Connecting shaft Coupling Torque
VWZ-30
KUZ-KK-16
4 Nm
VWZ-40 KUZ-KK-24 8 Nm
VWZ-60 KUZ-KK-32 15 Nm
VWZ-60V KUZ-KK-35 35 Nm
VWZ-80 KUZ-KK-45 70 Nm
VWZ-100 KUZ-KK-60 120 Nm

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Fig. 9: Installation of connecting shafts
CAUTION
Axial joining force!
Damage to the roller bearings, circlips etc.
Use a suitable fixture to draw the connecting parts together.
Do not apply blows or impacts to the shaft extensions.
3. Pull the couplings KUZ (couplings without half shells) on to the
shaftextensions. Tighten the set screw to the following torques:
Size KUZ-.. Set screw Torque
09, (14) M4 1.5 Nm
24, 28 M5 2.0 Nm
14, 19, 38 M6 4.8 Nm
45, 55, 60 M8 10 Nm
70, 75, 90 M10 17 Nm
For increased security the set screw can be secured using “medium
strength” thread locking agent.

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6.3 Fitting the motor
 The ZIMM Actuator must be installed.
CAUTION
Moving parts!
Injuries due to rotating parts.
Switch off the entire system and secure it against switching on again.
Fig. 13: Installing the motor
1. Fit the motor flange (1) to the ZIMM Actuator and bolt it into place.
2. Fit the coupling halves (2) to the gearbox shaft and bolt them into
place.
3. Attach the coupling star (3).
4. Pull the motor-side coupling halves (4) on to the motor shaft.
5. Attach the motor (5) to the motor flange and bolt it into place.
6. Fit the motor-side coupling halves (6) as follows:
– Slide them on to the gearbox-side coupling halves, leaving
1 mm axial play.
– Tighten the securing bolt (7).
– If the coupling halves cannot be slid on to the motor shaft:
Adjust the position before step 5 and tighten them.
7. Seal the assembly opening in the motor flange with a suitable
covering material.

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6.4 Connecting the electrical components
WARNING
Electric shock!
Electric shock can lead to death or serious injuries.
Allow only skilled electricians to work on the electrics.
Comply with the basic rules:
– Deenergise the system.
– Secure it against switching on again.
– Ensure all phases are electrically dead.
– Earth and short-circuit the system.
– Cover any adjacent parts that are still live.
6.4.1 Motor
 The motor (if supplied) must be installed.
1. Open the motor terminal box. The connection assignment is shown
within the motor terminal box.
2. Connect the motor in accordance with the circuit diagram.
6.5 Trial running
 The system must be installed and aligned.
 The spindle must be greased (for more information see section
"7.2 Lubrication", page 27).
CAUTION
Lateral forces due to incorrect alignment!
Damage to the gearbox and spindle.
1. If the alignment is defective: Correcting the alignment, see
section 6.6, page 22.
2. Repeat the trial run.
High forces are generated!
Damage to the ZIMM Actuator.
Make sure that the limit switches or end positions are not exceeded.
Make sure that attachments do not collide with other parts.