Zimmer CSR Series User manual

INSTALLATION AND
OPERATING INSTRUCTIONS
Handling
technology
CSR series
collision protection
THE KNOW-HOW FACTORY

INSTALLATION AND OPERATING INSTRUCTIONS: CSR series collision protection
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: [phone] ● Fax: [phone] ●www.zimmer-group.de
DDOC00267 enu / 2018-03-13 / a
 1.Installation,commissioning,maintenanceandrepairsmayonlybeundertakenbyqualiedexpertsinaccordancewith
these installation and operating instructions.
 2.ThecollisionprotectionoftheCSRseriesisstate-of-the-art.Itisttedtoindustrialmachinesandusedtoholdtoolsor
mounting pieces.
Hazards can originate from the collision protection only if,
forexample, -Itistted,usedormaintainedimproperly
- It is not used for its intended purpose
- The local regulations (legislation, guidelines, directives), such as the EC Machinery Directive,
- The Accident Prevention Regulations and installation and operating instructions are not observed.
 3.Thecollisionprotectionmaybeusedonlyinaccordancewithitsintendedpurposeandtechnicaldata.
ZIMMER GmbH shall accept no liability for any damage caused by improper use.
 4.AnyuseotherthantheintendeduserequireswrittenapprovalfromZimmerGmbH
5. Do not reach into the operating range of the collision protection or machine.
 6.Makesurethatthetransmissionlinesaredisconnectedbeforeyout,set,retool,maintainorrepairthecollisionprotec-
tion.
 7.Incaseofmaintenance,retrottingorexpansionwork,removethecollisionprotectionfromthemachineandcarryout
theworkoutsidethedangerzone.
8. When commissioning or testing, make sure that the machine cannot be actuated by mistake.
 9.Modicationstothecollisionprotection,suchasaddingboreholesorthreads,maybemadeonlywithpriorapproval
from ZIMMER GmbH.
 10.Thespeciedmaintenanceintervalsandcompressedairqualityspecicationsaretobeobserved;alsorefertothe
Maintenancesection.Whenthecollisionprotectionisusedunderextremeconditions,themaintenanceintervalmustbe
adapteddependingontheextentofthecontamination.Pleasecontactourhotlineforthispurpose.
 11.Useofthecollisionprotectionunderextremeconditions,suchasaggressiveliquidsandabrasivedust,issubjecttoprior
approval from Zimmer GmbH
 12.Whendisassemblingthecollisionprotection,exerciseincreasedcautionduetothealways present spring tension. This
workistobeperformedbyZimmer'scustomerservicedepartment.
1. Supporting documents
NOTE:
Thefollowingdocumentsareavailablefordownloadonourwebsite.Onlythedocumentscurrentlyavailable
onthewebsitearevalid.
• Catalog
• Drawings,performancedata,informationaboutaccessoryparts,etc.
• Technical data (data sheets)
• GeneralTermsandConditionsofBusiness,includingwarrantyinformation
2. Proper use
TheCSRcollisionprotectionisdesignedforoperationwithcompressedaironly.Itisnotsuitedforoperationwithothermediasuch
as liquids or gases. Proper use for CSR collision protection is in closed spaces for protecting the tool and/or the machine during a
collision or overload. It is not suitable for use as an active compensation module.Itisnotsuitablefordirectcontactwithperishable
goods.
NOTE:
  ThecollisionprotectionoftheCSRseriesmayonlybeusedinitsoriginalstate,withoriginalaccessories,
withoutanyunauthorizedchangesandwithinthescopeofitsdenedparametersforuse.
Zimmer GmbH shall accept no liability for any damage caused by improper use.
OnlytheaccessoriespermittedfortheCSRtypeseriesareallowedtobeinstalledonthecollisionprotection.
Regarding this, see the Handling Technology catalog
3. Safety notes

INSTALLATION AND OPERATING INSTRUCTIONS: CSR series collision protection
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: [phone] ● Fax: [phone] ●www.zimmer-group.de
DDOC00267 enu / 2018-03-13 / a
4. Function
Thepistonismovedintoitshomepositionbyllingtheinternalpneumaticcylinders.Itcanbepressedoutofthispositionbyexternal
forces.Airowsoverthepressuremembraneintothesurroundingsduringthisprocess.
Thiscausesapressuredropinsidethepneumaticcylinder,whichleadstotheintegratedproximityswitchbeingtriggered.Thesignal
fromtheintegratedproximityswitchcanbeusedasanEMERGENCYSTOPsignalforthemachine.
Afteractivation,thecompensatingangehastobeputintothehomepositionbyhand.
Thehomepositionisreachedoncethetriangleplacedonthehousingandthecompensatingangeareushwitheachotheragain.
1: Pneumatic connection
2: Robot ange
PitchcircleinaccordancewithENISO9409-1
3: Drive
Single-acting pneumatic cylinder
4: Force transmission
Directandlow-lossviathepistonsurface
5: Pressure dierential switch
Indirect overload recognition
6: Sensors
Inductiveproximityswitch
7: Connecting ange
8: Overload recognition ...
...whenthereisstressintheZdirection
...deectionwhenthereistorsionalstress
5. Technical data
Technical data varies by type and variant.
For the technical data, refer to the valid catalogs or the product data sheets.
Thesemulti-pagedatasheets(seeexampleimagetotheright)contain
- a product description,
- the Technical data,
 -adimensionaldrawingand
- the available accessories.
Thefollowingdatasheetsareavailablefordownloadonourwebsite:
www.zimmer-group.de
Product designation:
Type designation
Parameter for the pitch circle diameter
ontherobotangeinmm[ENISO9409-1]
CSR 
8
6
1
7
5
1
5
4
6
8
2
3
7

INSTALLATION AND OPERATING INSTRUCTIONS: CSR series collision protection
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: [phone] ● Fax: [phone] ●www.zimmer-group.de
DDOC00267 enu / 2018-03-13 / a
bl
bm bn
NOTE:
  Itismandatorytoobservethespeciedlengthofthemountingscrewsandthepermittedtighteningtorque!
DANGER:
  RiskofinjuryincaseofunexpectedmovementofthemachineorsystemintowhichtheCSRcollisionprotectionis
to be installed.
  ►Switchofftheenergysupplytothemachinebeforeallwork
  ►Securethemachineagainstbeingswitchedonunintentionally
  ►Checkthemachineforanyresidualenergy
The attachment options 9on both sides of the collision protection, robot
ange2andconnectingange7,aswellastheassociateddimensionsare
shownontherespectiveproductdatasheets.
See Technical data
Imagetotheright:CSR100example
In all 3 directions the damping behavior of the collision protection depends on
the amount of the pressurization.
Thecorrespondingdiagramsareindividuallyshownontheproductdatasheets
for each design size and each load condition.
See Technical data
Thediagramsshowtheforcesandtorquesasafunctionofthependingpres-
sure.
- blForcesforaverticalloadcase[Zdirection]:Fain[N]
- bmTorquesforanaxialloadcase[Xdirection]:Txin[Nm]
- bn Torques for a torsional load case: Trin[Nm]
Fa
Tx
Tr
6. Installation
9
2Robotange
7Connectingange

INSTALLATION AND OPERATING INSTRUCTIONS: CSR series collision protection
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: [phone] ● Fax: [phone] ●www.zimmer-group.de
DDOC00267 enu / 2018-03-13 / a
6.3 Installing the pneumatic connection and sensor
The pneumatic connection 1andthecorrespondingdimensionsareshownon
the respective product data sheets.
See Technical data
►Screwtheconnectingelementintotheconnection1
The respective matching connecting elements are available as accessories.
Theinductiveproximityswitch6generatesasignalthatcanbeusedtoevaluate
overload recognition.
This can be used to create an automatic emergency-stop situation on the system.
►Pushtheinductiveproximityswitchintotheholdergm
►Clamptheproximityswitchwiththescrewsgn using a maximum of 0.8 Nm
►Plugtheconnectingcableintothesensorandscrewitintoplace
The respective connecting cables are available as accessories
Beforeinstallingthecustomapplication,makesurethatitisofsuitableweight
and dimensions for the selected collision protection.
Thefollowingstepsshouldbeperformedtoinstallthecustomapplication
:
►Positionthecustomapplicationusingthestraightpinhm on the connecting
ange7
►Securethecustomapplicationwithsocketheadcapscrewshn of strength
class 8.8
Thecollisionprotectioncanbeinstalledontherobotinaccordancewith
ENISO9409-1usingthestandardizedconnectingange2.
When the mounting surface has a diameter:
< 100 mm, the permitted unevenness is < 0.02 mm,
> 100 mm, the permitted unevenness is < 0.05 mm.
Thefollowingstepsshouldbeperformedtoinstallthecollisionprotection:
►Removetherobotangeonthehousingandpositionitontherobotarmusing
the provided cylinder pin cm
►Installtherobotangeontherobotusingtheprovidedscrews cn
►Reinstallthecollisionprotectionontherobotangeusingthescrews co
6.1 Installing on the robot
6.2 Installing the customer-side application
2 cn co cm
7 hm hn
1 gn gm 6

INSTALLATION AND OPERATING INSTRUCTIONS: CSR series collision protection
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: [phone] ● Fax: [phone] ●www.zimmer-group.de
DDOC00267 enu / 2018-03-13 / a
7. Accessories
Inductiveproximityswitch
M8 connector
NJ8-E2S-05
Included in the CSR's scope of delivery
- Pneumatic connection,
straight threaded connection
- Pneumatic connection
angledtting,quickconnectstyle
6
1
Availability of accessories depends on type and variant. All accessory articles are available in variants matching the type and design
size of the respective CSR collision protection.
Forexactdataonavailability,refertotheproductdatasheets.Thefollowingdatasheetsareavailablefordownloadonourwebsite:
www.zimmer-group.de
The collision protection of the CSR series is maintenance-free.
Thismaintenance-freeoperationisensuredunderthefollowingconditions:
 •DrivewithlteredcompressedairinaccordancewithENISO8573-1:2001,Class2.4.1.
• Clean environment
 •Useinaccordancewithperformancedata
8. Maintenance
Even though the collision protection is, as mentioned, maintenance-free, perform a regular monthly check for any corrosion, damage
or dirt.
Clean the collision protection as needed using a commercially available machine cleaning agent and then apply an anti-corrosion
agent to the housing.
INFORMATION:
Complete disassembly of the collision protection for maintaining the seal must be carried out only by the Service
department of ZIMMER GmbH.
Straight plug-in
connector,
cable 5 m
M8 socket, KAG500
Angled plug-in
connector,
cable 5 m
M8 socket, KAW500
Hexagonsockethead
capscrews
Included in the CSR's scope of delivery
1 6 cn gogp
go gp
cn

INSTALLATION AND OPERATING INSTRUCTIONS: CSR series collision protection
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: [phone] ● Fax: [phone] ●www.zimmer-group.de
DDOC00267 enu / 2018-03-13 / a
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
We hereby declare that the incomplete machine described below
Product designation: collision protection
Type designation: CSR 
Wealsodeclarethatthespecic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 the machine or system in which the incomplete machine is to be
installed has been determined to satisfy the conditions of the Machinery Directive 2006/42/EC and the EC Declaration of
Conformity has been produced in accordance with Annex II 1 A.
satises 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.
9. Declaration of incorporation intermsoftheEUMachineryDirective2006/42/EC(AnnexII1B)
Authorized representative for compiling the rele-
vant technical documents
Kurt Ross Seemanufacturer'saddress Rheinau, Germany, 2014-01-16 Martin Zimmer
First name, last name Address (Place and date of issuance) (Legally binding signature)
Managing Director
Thefollowingharmonizedstandardshavebeenused:
DIN EN ISO 12100:2011-03 Safety of machinery – General principles for design - Risk assessment and risk reduction
•DINENISO4414-2011  Pneumaticfluidpower–Generalrulesandsafetyrequirementsforsystemsandtheir
components

INSTALLATION AND OPERATING INSTRUCTIONS: CSR series collision protection
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●Phone: [phone] ● Fax: [phone] ●www.zimmer-group.de
DDOC00267 enu / 2018-03-13 / a
10. Your notes