Zimmer ZK1000 Series User manual
INSTALLATION AND OPERATING INSTRUCTIONS: Cutting tongs, pneumatic, ZK1000 series
Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau ● Germany ●+49 7844 9138 0 ● +49 7844 9138 80 ● www.zimmer-group.com
Installation and
operating instructions
ZK1000 series
DDOC01013
Index a
EN/2022-19-07
Im Salmenkopf 5
77866 Rheinau
Germany
+49 7844 9138 0
+49 7844 9138 80
www.zimmer-group.com
1. Supporting documents
NOTICE
Read through the installation and operating instructions carefully before installing the product!
The installation and operating instructions contain important notes for your personal safety. They must be read and
understood by all persons who work with or handle the product during any phase of the product lifetime.
The documents listed below are available for download on our website (www.zimmer-group.com).
Only those documents currently available on the website are valid.
• Catalogs, drawings, CAD data, performance data
• Information on accessories
• Detailed installation and operating instructions
• Technical data sheets
• General Terms and Conditions of Business with specications for the warranty entitlement
2. Safety notices
CAUTION
Risk of injury and material damage in case of non-compliance
Installation, commissioning, maintenance and repairs may only be performed by qualied specialists in accordance
with these installation and operating instructions.
The product is state-of-the-art. It is mounted to industrial machines and is used to hold tools.
The product can only become a source of hazard if, for example:
• The product is not properly installed, used or maintained.
• The product is not used for its designated purpose.
• The locally applicable regulations, laws, directives or guidelines are not observed.
The product may only be used in accordance with its intended use and technical data. Zimmer GmbH shall accept
no liability for any damage caused by improper use.
Any use other than the intended use requires written approval from Zimmer GmbH.
Make sure that the power supply is disconnected before you install, retool or service the product.
Zimmer GmbH recommends performing maintenance tasks, renovation work or attachment work outside of the
machine's danger zone when possible.
When commissioning or testing, make sure that the product cannot be actuated by mistake.
Modications to the product, such as adding drilled holes or threads, may be made only with prior approval from
Zimmer GmbH.
The specied maintenance intervals are to be observed; also refer to the "Maintenance" section. When the product is
used under extreme conditions, the maintenance interval must be adapted.
Use of the product under extreme conditions, such as aggressive liquids and abrasive dusts, is subject to prior
approval from Zimmer GmbH.
Do not reach into the operational range of the product!
3. Proper use
NOTICE
The product is only to be used in its original state with its original accessories, with no unauthorized changes and
within the scope of its dened parameters for use.
Zimmer GmbH shall accept no liability for any damage caused by improper use.
The product is designed exclusively for pneumatic operation.
The product is designated for use in enclosed rooms for separating dened materials.
Direct contact with perishable goods/food is not permitted.
It is not suited for operation with other media such as liquids or gases.
4. Personnel qualication
Installation, commissioning and maintenance may only be performed by qualied personnel. These persons must have read and
understood the installation and operating instructions in full.
5. Product description
5.1 Forces and torques
INFORMATION
For information on forces and torques, please visit our website.
Zimmer Customer Service is available to provide you with assistance if you have any further questions.
5.2 Type plate
A type plate is attached to the housing of the product.
The conrmation number and the article number are indicated on this type plate.
The conrmation number should be assigned to the project.
• Article number: am
• Conrmation number: an
INFORMATION
Please state the conrmation number in the event of damage or a complaint.
Zimmer Customer Service is available to provide you with assistance if you have any further questions.
6. Function
The function is based on a single-acting vented pneumatic piston with spring return. As a result of its structure, the ZK1000
series product reduces interference contours, thereby enabling simple integration into the machine design.
The ZK1000 series makes it possible to use different cutting geometries and materials.
The ZK1000 series has an integrated magnetic eld sensor. This ensures process reliability for sensing the positions and
transmitting them to the control system.
1Power supply ZK1000 product series
2
1
3
4
5
6
2Mounting and positioning
3Cutting insert
4Mounting clamp for magnetic eld sensor
5Magnetic eld sensor
6Housing
7. Installation
7.1 General installation information
WARNING
Risk of injury in case of unexpected movement of the machine or system into which the product is to be installed.
►Switch off the power supply to the machine before all work.
►Secure the machine against being switched on unintentionally.
►Check the machine for any residual energy.
CAUTION
Risk of injury in the event of unexpected movement of the product when the power supply is connected.
►Switch off the power supply to the product before all work.
►Secure the power supply against being switched on unintentionally.
►Check the power supply for any residual energy.
NOTICE
Switch off the power supply before any assembly, installation or maintenance work.
The product must be installed on a suitable mounting surface in accordance with the atness specications.
ÖPermissible atness imperfection: 0.03 mm
ÖThe locknut is included in the scope of delivery.
ÖStrength class of the locknut at least 8.8 DIN EN ISO 4762
ÖObserve the tightening torque of the locknut.
ÖZimmer GmbH recommends verifying the permitted load-carrying capacity of the required screw connections in accordance
with VDI 2230.
ÖMake sure the mounting surface is suciently rigid and at.
ÖThe exact positions can be found on the technical data sheet on our website www.zimmer-group.com.
7.2 Installing mechanic
The gripper can be installed on the mounting piece using the
screw thread 2and the locknutbl.
The following work steps must be observed during installation:
►Guide the product into the borehole on the mounting piece.
ÖIt is held using the mating part bp.
►Secure the product using the locknut bl.
ÖAttach the locknut blso that it is hand-tight.
►Align the product.
►Tighten the locknut blto the specied tightening torque. 2
bl
9
bp
7.3 Installing the power supply
Insert the screw connection 9into the designated connection.
NOTICE
Close off unused pneumatic connections with dummy plugs.
The authorized pneumatic connections that are available can be found in the accessories list, which is available on
our website.
The necessary ordering information can also be found there.
ÖUse compressed air in accordance with DIN ISO 8573-1 [4:4:4].
7.4 Installing/disassembling the cutting insert
7.4.1 Installation
The following work steps must be observed when installing the
cutting insert:
►Switch off the power supply to the product.
►Check the power supply for any residual energy.
►Guide the cutting insert bninto the housing 6.
►Secure the cutting insert bnusing the bearing pin bo.
►Secure the bearing pin bousing the lock washers bm.
7.4.2 Uninstallation
The following work steps must be observed when disassembling
the cutting insert:
►Switch off the power supply to the product.
►Check the power supply for any residual energy.
►Remove the lock washers bm.
►Pull out the bearing pin bo.
ÖIn doing so, hold the cutting insert bnsecurely.
►Take the cutting insert bnout of the housing 6.
bm
bn
bo
INSTALLATION AND OPERATING INSTRUCTIONS: Cutting tongs, pneumatic, ZK1000 series
Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau ● Germany ●+49 7844 9138 0 ● +49 7844 9138 80 ● www.zimmer-group.com
7.5 Installing accessories
NOTICE
Before installing an accessory, make sure it is suitable for use with the selected variant.
For information on all available accessories, please visit our website.
7.5.1 Installation example for a sensor bracket
7.5.2 Installation
The following work steps must be observed during installation:
►Insert the magnetic eld sensor btinto the sensor holder bs.
►Insert the magnetic eld sensor bttogether with the sensor
holder bsinto the adapter br.
►Push the complete package, including the mounting clamp,
onto the product4and secure it in place using the mounting
screw bq.
4
bq
br
bs
bt
8. Technical data
INFORMATION
For technical data, please visit our website.
This data varies within the series, depending on the specic design.
Zimmer Customer Service is available to provide you with assistance if you have any further questions.
8.1 Cutting diameters
INFORMATION
The cutting diameters specied in the technical data sheet are the maximum possible diameters that can be
accommodated and cut by the cutting tongs.
Due to the material properties/material grades, the diameter may be smaller.
Contact Zimmer Customer Service for the appropriate cutting tongs for a particular material.
9. Maintenance
CAUTION
Risk of injury caused by improper maintenance.
►During maintenance of the product, observe the locally valid workplace safety regulations.
►Only appoint trained personnel.
►Switch off the power supply.
Maintenance-free operation of the product is guaranteed for up to 5 million cycles.
The maintenance interval may shorten under the following circumstances:
• Operation with compressed air that does not comply with DIN ISO 8573-1 quality class [4:4:4]
• Dirty environment
• Improper use and use that does not comply with the power specications
• Ambient temperature above 60 °C
Even though the product is maintenance-free as mentioned above, perform a regular visual inspection to check for any damage
or contamination. Dismantling and reassembling the product without authorization may result in complications, as special
installation equipment is required in some cases. Zimmer GmbH shall not be liable in the event of unauthorized dismantling and
reassembling of the product or in the event of any malfunction or damage resulting from this.
10. Transportation/storage/preservation
►Transport and storage of the product must be done only with the original packaging.
►If the product has already been installed on the superordinate machine unit, care must be taken during transport to ensure
that no uncontrolled movements can occur. Before commissioning the machine after transport, check all power and
communication connections as well as all mechanical connections.
►If the product is stored for an extended period, the following points are to be observed:
• Keep the storage location as dust-free and dry as possible.
• Avoid temperature uctuations/observe and adhere to the temperature range.
• Avoid wind/drafts/water condensation formation.
• Store product packaged.
• During storage, it must be kept away from direct sunlight.
►Visually inspect all of the components.
►Remove all foreign substances.
►Close pneumatic connections using suitable covers.
11. Decommissioning and disposal
INFORMATION
When the product reaches the end of its operational phase, the product can be completely disassembled and
properly disposed of according to
material groups. Completely disconnect the product from the power supply. When
disposing of it, observe the locally applicable environmental provisions and codes and regulations for disposal.
12. Declaration of Incorporation
In terms of the EU Machinery Directive 2006/42/EC (Annex II 1 B).
Name and address of the manufacturer:
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • +49 7844 9138 80 •www.
zimmer-group.com
We hereby declare that the incomplete machine described below
Product designation: Cutting tongs, pneumatic
Type designation: ZK1000
satises the following basic requirements of the Machinery Directive 2006/42/EC:
No. 1.1.2., No. 1.1.3., No. 1.1.5., No. 1.3.2., No. 1.3.4., No. 1.3.7., No. 1.5.3., No. 1.5.4., No. 1.5.8., No. 1.6.4., No. 1.7.1., No. 1.7.4
The manufacturer has a complete list of the applied standards.
We also declare that the specic technical documents were produced in accordance with Annex VII Part B of this Directive. We
undertake to provide the market supervisory bodies with electronic versions of special documents for the incomplete machine
through our documentation department, should they have reason to request them.
The incomplete machine may only be commissioned if it has been ascertained, if applicable, that the machine or system in
which the incomplete machine is to be installed satises the requirements of Directive 2006/42/EC on Machinery and an
EC Declaration of Conformity has been drawn up in accordance with Annex II 1 A.
Authorized representative for the compilation of
relevant technical documents
Kurt Ross See manufacturer's address Rheinau, Germany,
11/10/2020
Martin Zimmer, Managing
Director
First name, last name Address Place and date of issuance Legally binding signature
This manual suits for next models
4
