Zimmer DKHS1000 Series User manual

www.zimmer-group.com
INSTALLATION AND
OPERATING
INSTRUCTIONS
DKHS1000 Series
Rotary clamping element
Hydraulic
DDOC00230
THE KNOW-HOW FACTORY

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary clamping element hydraulic DKHS1000 series
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
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INSTALLATION AND OPERATING INSTRUCTIONS: Rotary clamping element hydraulic DKHS1000 series
3
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
EN / 2020/08/31DDOC00230 / e
Content
1 Supporting documents......................................................................................................................................................... 4
2 Safety instructions................................................................................................................................................................. 4
3 Proper use ............................................................................................................................................................................. 5
4 Improper use ......................................................................................................................................................................... 5
5 Personnelqualication ......................................................................................................................................................... 5
6 Product description .............................................................................................................................................................. 6
6.1 Laser engraved type plate ..........................................................................................................................................................................................6
7 Funktion ................................................................................................................................................................................. 7
8 Technical data ....................................................................................................................................................................... 8
9 Tightening torque of mounting screws ............................................................................................................................... 8
10 Installation.............................................................................................................................................................................. 9
10.1 Installation of the mechanical system......................................................................................................................................................................10
10.2 Hydraulic diagram .....................................................................................................................................................................................................13
10.3 Deinstallation of the element....................................................................................................................................................................................13
11 Function check.................................................................................................................................................................... 13
12 Error diagnosis .................................................................................................................................................................... 14
13 Accessories/scope of delivery........................................................................................................................................... 14
14 Maintenance........................................................................................................................................................................14
15 Transportation/storage/preservation ................................................................................................................................ 15
16 Decommissioning and disposal......................................................................................................................................... 15
17 Declaration of Conformity .................................................................................................................................................. 16

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary clamping element hydraulic DKHS1000 series
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
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1 Supporting documents
HINWEIS
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 life cycle.
The documents listed below are available for download on our website www.zimmer-group.com:
• Installation and operating instructions
• Catalogs, drawings, CAD data, performance data
• Information on accessories
• Technical data sheets
• General Terms and Conditions of Business, including warranty information
ÖOnly those documents currently available on the website are valid.
2 Safety instructions
VORSICHT
Risk of injury in case of improper installation, commissioning, maintenance and improper use.
Non-compliance may result in severer injuries.
1. Installation,commissioning,maintenanceorrepairmayonlybeperformedbyqualiedspecialistsin
accordance with these installation and operating instructions.
2. The element 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.
3. Any use other than the intended use requires written approval from Zimmer GmbH.
4. Powersupplyfaults,e.g.duetopressureuctuations.
5. Missing or loose mounting screws.
6. When commissioning or testing, make sure that the element cannot be actuated by mistake.
7. Human error.
8. Failure to observe the safety and warning instructions during installation and commissioning.
9. In the event of maintenance, conversion or expansion work, remove the element from the machine and carry
out the work outside the danger zone.
10. Do not reach into the operating range of the element!

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary clamping element hydraulic DKHS1000 series
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3 Proper use
HINWEIS
Theproductistobeusedonlyinitsoriginalcondition,withoriginalaccessories,withoutanyunauthorizedmodi-
cation and within the agreed parameter limits and conditions of use. Any other or additional use is considered
improper.
►Operate the product only in accordance with the associated installation and operating instructions.
►Operate the product only in a technical condition that corresponds to the guaranteed parameters and
conditions of use.
ÖZimmer GmbH is not liable for any damages resulting from improper use. The user bears the sole risk.
Theelementmayonlybeusedinthefollowingareasor,morespecically,inthefollowingmachinesorsystems:
• The element is designed solely for torque absorption on rotating machine components.
• The clamping of the rotation axis may only take place in a static state.
• Theelementmayonlybeoperatedundertheconditionsspeciedinthetechnicaldatasheet.
• Theelementmayonlybeoperatedunderthepredenedinstallationandtolerancespecications.
• Theelementisdesignedforoperationwithhydraulicuidonly.
• The guide must be provided externally. The element does not feature any guide characteristics.
4 Improper use
Theelementmaynotbeusedinthefollowingareasor,morespecically,inthefollowingmachinesorsystems,without
further protective or control measures:
• Equipment used to transport persons (e.g. elevators)
• With loads suspended over persons
• Use as a brake or bearing is not permitted
• In vehicles
• Underwaterorinotheruids
• Corrosive environment (e.g. in connection with acids)
• Contact with abrasive media (e.g. grinding dust)
• Vacuum
• Direct contact with foods or other perishable goods
• Potentially explosive atmosphere
• Unauthorizedmodicationsmustnotbemade.
The rotary clamping element is not suitable for use with any other media, pressure ranges or as a service brake other than
thosespeciedintheapplicabledocuments.
INFORMATION
If you have further questions regarding the intended use or improper use of the element, please contact Zimmer
Customer Service.
5 Personnel qualication
Installation,commissioningandmaintenancemayonlybeperformedbyqualiedpersonnel.Thesepersonnelmusthave
read and understood the installation and operating instructions in full.

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary clamping element hydraulic DKHS1000 series
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
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6 Product description
The DKHS1000 series element is designed for the highly
rigidandprecisexingofrotationaxeswithhighangle
accuracy during torque absorption.
The element may only be used for the static clamping of
axes or shafts. The element must not be used as a bearing
or brake.
The rotary clamping element is a hydraulically operated
rotary clamp with a spring accumulator (NC).
The element is closed in the event of a loss of power
(pressureless)
ÖNC (Normally Closed).
6.1 Laser engraved type plate
Atypeplate,asalaserengraving,isa󹱺xedtothehousing
of the element.
The laser engraving includes the serial number, article
number and the adjustment dimension.
ÖIt is recommended to assign the serial number to your
project, in case any questions arise.
ÖExample:
• Article number: DKHS1xxx
• Serial number: 06-12345678
• Adjustment dimension [mm]: X,XX
DKHS1xxx
06-123456789
X,XX
INFORMATION
Please always state the serial number in the event of damage or a complaint.
Under no circumstances should the laser engraving on the element be removed or changed. Should the laser
engraving nevertheless be removed or changed, Zimmer GmbH is not liable for any damages or claims.
If you have any further questions, please contact Zimmer Customer Service.

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary clamping element hydraulic DKHS1000 series
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7 Funktion
Hydraulic pressure is applied to the housing. Under this pressure, the housing expands slightly and releases the shaft
connection, which is screwed to the rotation axis.
In the pressureless state, the housing resumes its original shape and clamps the shaft connection via the pretension
retained in the housing.
This pretension enables the holding torque absorption to be achieved in the clamped state.
The element is closed in a pressureless state and offers an integrated emergency function that ensures that all moving
components are held securely if the pressure drops or the entire system fails.
The element is not suitable for dynamic emergency braking.
Fig. 1: Cutaway view of the DKHS1000 series element
B
A
1Housing
2Housing connection
3Pressure chamber
4Sealing
5Hydraulic connection (A)
6Vent connection (C)
7Holding plate
8Clamping area
9Shaft connection
Fig. 2: DKHS1000 series element - cutaway view A
4
1
2
3
75
9
8
Fig. 3: DKHS1000 series element - cutaway view B
1
2
3
4
6
7
8
9

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary clamping element hydraulic DKHS1000 series
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
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8 Technical data
The element has a product service life (B10d value) of 5,000,000 cycles.
The B10d value is determined in accordance with ISO 19973-1 (dangerous failures with regard to the safety of machinery).
INFORMATION
For technical data, please refer to our website at www.zimmer-group.de/de/lt-faq.
Thisdatavarieswithintheseries,dependingonthespecicdesign.
If you have any further questions, please contact Zimmer Customer Service.
Exemplary explanation of the holding torque:
Theexemplarytechnicalspecication“Holdingtorque1”:1000Nm”meansamaximumrotationoftheshaftof1arcsec
(angular second) under a torque effect of 1000 Nm.
Theexemplarytechnicalspecication“Holdingtorque5”:1800Nm”meansamaximumshaftrotationof5arcsec(angular
second) under a torque effect of 1800 Nm.
9 Tightening torque of mounting screws
Thespeciedtighteningtorqueappliestomountingpiecesmadeofsteel.Whenusingmaterialswithalowerstrength(e.g.
aluminum), the tightening torques must be calculated separately.
Thread Tightening torque (ISO 4762)
M6 17.3 Nm
M8 42,1 Nm
HINWEIS
To install the element only mounting screws of strength class 12.9 may be used.
Using of other strength classes may result in loss of maximum clamping force, element failure, property damage
and personal injury.
If you have any further questions, please contact Zimmer Customer Service.

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary clamping element hydraulic DKHS1000 series
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Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
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10 Installation
WARNUNG
Risk of injury in case of unexpected movement of the machine or system into which the element 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 pressure.
Risk of injury during overhead assembly work
►For overhead assembly work, a suitable lifting or holding device must be chosen.
ÖThe weight within the series may vary.
VORSICHT
Risk of injury in the event of unexpected movement of the element when the energy supply is connected.
►Switch off the power supply to the machine before all work.
►Secure the power supply against being switched on unintentionally.
►Check the power supply for any residual energy.
HINWEIS
• The adjustment (± 5 µm) of the axle or shaft/shim is absolutely mandatory. The dimensions, shape and
positiontolerancesbetweentheshaftandelementmustbeadheredtowithinthespeciedanddened
parameters. Any deviation can result in damage to the element during continuous operation.
• Duringinstallation,ensurethatthemountingpieceissu󹱺cientlyrigidandatinaccordancewithMachinery
Directive 2006/42/EG.
• Ensure that the cutting rings and O-rings are inserted on the spotface.
• All mounting points on the element must be used.
• Tighten the mounting points crosswise.
• Hydraulic connection A = pressurisation
• Vent connection C = vent

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary clamping element hydraulic DKHS1000 series
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
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10.1 Installation of the mechanical system
bl
bm
bl
bn

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary clamping element hydraulic DKHS1000 series
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MOUNTING SURFACE
►Screw-on surface of housing
ÖOuter diameter of the rotary clamping element minus 40 mm
The minimum mounting surface with which the element may be mounted on the adjacent construction is minus
40 mm of the outer diameter of the housing of the rotary clamping element.
►Mounting surface for shaft connection:
ÖInner diameter of the shaft connection + 40 mm (minimum + 22 mm)
The minimum mounting surface with which the element may be mounted on the shaft connection is plus 22 mm
of the internal diameter of the shaft connection of the rotary clamping element.
Zimmer GmbH recommends a mounting surface of + 40 mm!
SURFACE ROUGHNESS
ThesurfaceofthereectionmusthavearoughnessofatleastRa1.6.
ÖO-ring and cutting ring
HINWEIS
Vertical mounting:
Vent connection C must face upwards for vertical mounting.
ÖThe built-in sealing plug of vent connection C is not suitable for sealing!
The following work steps must be observed when installing at the adjacent construction bm:
►Before mounting the element, the pressure setting and operability of the pressure relief valve must be checked.
► The element has to be installed on a suitable mounting surface in accordance with the specications for atness and
overall running.
ÖPermitted unevenness and total running < 0.02 mm
ÖMakesurethemountingsurfaceissu󹱺cientlyrigidandlevel.
0.02 0.01 A
A
0.02 0.01 A
Abstimmmaß

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary clamping element hydraulic DKHS1000 series
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►The adjustment of the tuning disk bntothespeciedtuningdimension.
ÖSee the laser engraving for the adjustment dimension of the element.
►Check whether all cutting rings and O-rings are properly inserted in the element.
►Remove the plugs from hydraulic connections A 5and vent connection C 6.
►Set the element onto the tuning disk bnand mounting piece bm.
ÖEnsure that the hydraulic connection A 5and the vent connection C 6arelocatedonthereectivesurfaces.
►Loosely attach housing 1and shaft connection 8to adjacent construction bmand tuning disk bnusing mounting
screws bl.
Under no circumstances should pressure be applied to the element until all screws have been tightened to the
required torque.
ÖScrew-in depth = at least 1.2. x Ø
ÖThe mounting screws are not included in the scope of delivery (optional accessories).
ÖStrengthclassofthemountingscrewsatleast12.9DINENISO4762.
ÖTheelementiscenteredviathescrewttings.
ÖMaximum tolerance range of the tuning disc ± 5 µm.
►After loosely screwing on with a plastic hammer or similar, hit the housing of the rotary element from above at the height
of the cutting ring positions in order to press it between the housing and the adjacent construction.
►Tighten the mounting screws blwiththespeciedtighteningtorquetothemountingpiecebm.
ÖTightenthemountingscrewsrstonthehousingandthenontheshaftconnection.
ÖObserve the tightening torque of the mounting screws.
ÖTighten the mounting screws crosswise.
►Deaeratetheelementbyushingitwithhydraulicoil.
ÖHydraulic connection A = pressurisation
ÖVent connection C = vent
►Insert low pressure hydraulic oil into the element through hydraulic connection A 5.
►Flush the element for a time until the hydraulic oil exits via vent connection C 6bubble-free.
►Close the vent connection C 6before operation on the adjacent construction bmwithasuitableameproofseal.
►Perform a functional test.
ÖThe procedure of the functional test is described in Section 11.
HINWEIS
Non-compliance may result in property damage.

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary clamping element hydraulic DKHS1000 series
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10.2 Hydraulic diagram
INFORMATION
The illustrated hydraulic diagram is an exemplary representation.
If you have any further questions, please contact Zimmer Customer Service.
bn Rotary clamping element
bo Hydraulic directional valve
bp Hydraulic pump
bq Oil tank
br Pressure regulator
10.3 Deinstallation of the element
Deinstallation of the elements is carried out in the reverse order of that described in Chapter 10.1.
11 Function check
After the element has been properly installed, check the following characteristics to determine whether it is ready to be
operated:
• If the element is under pressure, check the ease of movement by turning the shaft slowly.
• If the element is not under pressure, check the clamping process by applying the required torque to the shaft.
• Check the spotface for leaks at maximum pressure by performing a visual inspection.
• Checkthehydrauliccircuittoensuretheabsenceofbubbles(ushingthehydrauliccircuit).
• Checkallmountingscrewsforthespeciedtighteningtorque.
• The element must not increase the torque of the rotating parts on the machine when open.
INFORMATION
The function of the element can be tested by depressurizing the element and then applying a torque less than or,
at most, equal to the holding torque of the element.
If any strain on the axis or shaft can be detected, it must be assumed that the inner elements are worn.
If you have any further questions, please contact Zimmer Customer Service.

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary clamping element hydraulic DKHS1000 series
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WARNUNG
Risk of injury from hot surfaces.
►Touching the element immediately after operation at the maximum allowable operating temperature can
cause burns.
►Wear personal protective equipment.
ÖWearing PPE is recommended.
Lubricants in the clamping area
If the element comes into contact with lubricants, perform another functional test to check whether the element
still reaches the required holding torque.
ÖIf the element does not reach the required holding torque, clean the clamping area from all lubricants and
check it by performing a functional test.
12 Error diagnosis
INFORMATION
For an accurate and detailed overview of possible faults and their remedies, visit our website at www.
zimmer-group.de/de/lt-faq.
If you have any further questions, please contact Zimmer Customer Service.
13 Accessories/scope of delivery
INFORMATION
If any accessories not marketed or authorized by Zimmer GmbH are used, the function of the element cannot be
guaranteed.
TheaccessoriesfromZimmerGmbHarespecicallyttedfortheindividualelements.
Please refer to our website for information on corresponding accessories.
14 Maintenance
Whenusedasintended,therearenoknownlimitationsuntilthespeciednumberofcycleshasbeenreached.
The service life may shorten under the following circumstances:
• Dirty environment.
• Improperuseandusethatdoesnotcomplywiththepowerspecications.
• Incorrect installation.
• Failure to comply with the operating temperature.
Even though the element is maintenance-free as mentioned above, perform a regular visual inspection to check for any
corrosion, damages or contamination.
Zimmer GmbH shall not be liable in the event of unauthorized dismantling and reassembling of the element or in the event
of any malfunction or damage resulting from this.

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary clamping element hydraulic DKHS1000 series
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15 Transportation/storage/preservation
►Transport and storage of the element must take place only using the original packaging or similar packaging.
►If the element is already mounted onto the superordinate machine unit, ensure that during transport the element is not
subjected to any load (for example, if there is a swivel bridge at the top).
ÖBefore commissioning the machine after transport, check all power connections and all mechanical connections.
►If the product is stored for an extended period, the following points are to be observed:
ÖKeep the storage location as dust-free and dry as possible.
ÖAvoidtemperatureuctuations/observeandadheretotheoperatingtemperature.
ÖAvoid wind/drafts/water condensation formation.
ÖPackage the product so that it is protected against corrosion.
ÖDuring storage, it must be kept from direct sunlight.
►Clean all components. There must be no soiling left on the components.
►Visually inspect all of the components.
►Remove all foreign objects.
►Apply corrosion protection in the correct manner.
►Close hydraulic connections by using suitable covers.
►Cover the product in a dustproof manner with weather-resistant, tear-resistant foil.
ÖIf necessary, also include desiccant under the foil.
16 Decommissioning and disposal
INFORMATION
If the element reaches the end of its service life, it can be disposed of. Completely disconnect the element from
the power supply. When disposing of it, observe the locally applicable environmental regulations and codes and
regulations for disposal..

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary clamping element hydraulic DKHS1000 series
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17 Declaration of Conformity
In terms of the EC Directive 2014/30/EC on electromagnetic compatibility
Name and address of the manufacturer:
Zimmer GmbH
77866 Rheinau, Germany, Im Salmenkopf 5
[phone]
[phone]
www.zimmer-group.com
We hereby declare that the products described below
Product designation: Rotary clamping element, hydraulic
Type designation: DKHS1000-Series
conform to the requirements of the Electromagnetic Compatibility Directive 2014/30/EU in its design and the version we put
on the market.
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 13849-1 /13849-2 Safety of machinery – Safety-related parts of control systems (Appendix C.1 / C.2 of
EN 13849-2, Chap. 6.2.4, Para. b of EN 13849-1)
DIN EN ISO 4413 Safety-related requirements for hydraulic systems and their components
A full list of applied standards can be obtained from the manufacturer.
Authorized representative for the compilation of
relevant technical documents
Michael Hemler See manufacturer's address Rheinau, Germany, 2020-08-31 Martin Zimmer
First name, last name Address (Place and date of issuance) (Legally binding signature)
Managing Partner