Zimmer DKPS1000 Series User manual

INSTALLATION AND
OPERATING
INSTRUCTIONS
Rotary clamping element,
pneumatic
DKPS1000 series
DDOC01621
THE KNOW-HOW FACTORY
www.zimmer-group.com

3
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com
Content
1 Supporting documents ............................................................................................................................................................... 4
1.1 Notices and graphics in the installation and operating instructions ...............................................................................................................................4
2 Safety notices............................................................................................................................................................................... 5
3 Proper use .................................................................................................................................................................................... 6
4 Personnelqualication................................................................................................................................................................ 6
5 Product description ..................................................................................................................................................................... 6
5.1 Type plate .............................................................................................................................................................................................................................6
6 Functional description ................................................................................................................................................................. 7
7 Technical data .............................................................................................................................................................................. 7
8 Accessories/scope of delivery ................................................................................................................................................... 8
9 Transportation/storage/preservation......................................................................................................................................... 8
10 Installation .................................................................................................................................................................................... 9
10.1 Installing the product.........................................................................................................................................................................................................10
10.1.1 Installing the product with energy supply from above......................................................................................................................................12
10.1.2 Installing the product with energy supply from below......................................................................................................................................13
10.2 Installing the sensors.........................................................................................................................................................................................................16
10.3 Installing accessories ........................................................................................................................................................................................................16
11 Commissioning ..........................................................................................................................................................................17
11.1 Checking operational readiness.......................................................................................................................................................................................17
12 Maintenance............................................................................................................................................................................... 18
13 Decommissioning/disposal ...................................................................................................................................................... 18
14 Declaration of Conformity ......................................................................................................................................................... 19

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1 Supporting documents
NOTICE
Read through the installation and operating instructions before installing or working with 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.
• Installation and operating instructions
• Catalogs, drawings, CAD data, performance data
• Information on accessories
• Technical data sheets
• General Terms and Conditions, including warranty information.
ÖOnly those documents currently available on the website are valid.
In these installation and operating instructions, "product" refers to the product designation on the title page!
1.1 Notices and graphics in the installation and operating instructions
DANGER
This notice warns of an imminent danger to the life and health of people. Ignoring these notices can lead to
serious injury or even death.
►You absolutely must comply with the described measures for avoiding these dangers!
ÖThe warning symbols are assigned according to the type of danger.
WARNING
This notice warns of a situation that is potentially hazardous to personal health. Ignoring these notices can cause
serious injury or damage to health.
►You absolutely must comply with the described measures for avoiding these dangers!
ÖThe warning symbols are assigned according to the type of danger.
CAUTION
This notice warns of a situation that is potentially hazardous for people or that may result in material or environ-
mental damage. Ignoring these notices may result in slight, temporary injuries or damage to the product or to the
environment.
►You absolutely must comply with the described measures for avoiding these dangers!
ÖThe warning symbols are assigned according to the type of danger.
NOTICE
General notices contain usage tips and valuable information, but no warnings of dangers to health.
INFORMATION
Thiscategorycontainsusefultipsforhandlingtheproducte󹱺ciently.Failuretoobservethesetipswillnotresult
in damage to the product. This information does not include any information relevant to health or workplace
safety.
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

5
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qualiedspecialistsin
accordance with these installation and operating instructions.
The product is state-of-the-art.
The following are examples of situations in which the product may cause a hazard:
• 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 these installation and operating instructions and the
product'stechnicaldata.Anychangesoradditionstotheintendeduseoftheproduct,aswellasmodications
to the product, such as those in the following examples, require the written permission of the manufacturer:
• Useoftheproductunderextremeconditions,suchasaggressiveuidsorabrasivedusts
• Use of the product as an emergency brake
• Additional drilled holes or threads
ÖZimmer GmbH shall accept no liability for any damage caused by improper use. The operator bears sole
responsibility.
►Make sure that the power supply is disconnected before you mount, adjust, modify, maintain or repair the
product.
►Avoidenergysupplyfaults(e.g.duetopressureuctuations).
►Whenever work is carried out on the product, make sure that the product cannot be actuated by mistake.
►Perform maintenance tasks, renovation work or attachment work outside of the machine's danger zone when
possible.
►Do not reach into the operational range of the product.
►Always adhere to the required maintenance intervals.
►When using the product under extreme conditions, adjust the maintenance interval according to the degree of
contamination.
►Avoid using the product with missing or loosened mounting screws.
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

6
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 stipulated parameter limits and operating conditions.
Any other or secondary use is deemed improper.
►Operate the product only in compliance with the associated installation and operating instructions.
►Operate the product only when it is in a technical condition that corresponds to the guaranteed parameters
and operating conditions.
ÖZimmer GmbH shall accept no liability for any damage caused by improper use. The operator bears sole
responsibility.
The product is designed exclusively for pneumatic operation.
The product is designed solely for torque absorption on rotating machine components.
The product may only be used for the static clamping of axes or shafts.
The product is not suited for use as a bearing or brake.
The product does not feature any guide characteristics. Guidance must be performed externally.
4 Personnel qualication
Installation, commissioning and maintenance may only be performed by trained specialists. These persons must have read
and understood the installation and operating instructions in full.
5 Product description
Theproductisapneumaticallyoperatedrotaryclampingelement.
Theproductxatesrotationaxeswithhighangleaccuracyduringtorqueabsorption.
The product has a spring energy accumulator and is closed in the deenergized state.
5.1 Type plate
Atypeplate,asalaserengraving,isa󹱺xedtothehousingofthe
product.
XXXX1234
01-123456789
am
an
Thearticlenumberandconrmationnumberareshownonthetype
plate.
am Article number
an Conrmationnumber
INFORMATION
►Do not remove the laser engraving on the product.
►Do not modify the laser engraving on the product.
ÖZimmerGmbHshallacceptnoliabilityforpossibledamageorcomplaintsaboutaproductwithamodiedor
removed laser engraving.
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

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6 Functional description
The housing is pressurized with pneumatic pressure which sets two opposite pistons into motion. These each put pressure
onpretensioneddiskspringsanddeectsthem.
The inner diameter of the product increases slightly from this and releases the shaft.
The product is closed in a pressureless state that ensures that all moving components are held securely if the pressure
drops or the entire system fails.
1Case
2Clamping area
1
2
7 Technical data
INFORMATION
• B10d value: 3 million cycles
INFORMATION
►Youcanndtheinformationinthetechnicaldatasheetonourwebsite.
Thisdatavarieswithintheseries,dependingonthespecicdesign.
►Please contact Zimmer Customer Service if you have any questions.
INFORMATION
Theholdingtorqueisspeciedinthetechnicaldatasheet.
• Theaccuracyofthespeciedholdingtorquecorrespondstoaninstallationsize-independenttangential
motion of the shaft of 2 µm under load.
• The maximum holding torque corresponds to the maximum holding torque that may be applied to the product
during safety operating mode or an emergency stop.
• The maximum holding torque can also be used for applications for which angle accuracy is not required.
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

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8 Accessories/scope of delivery
INFORMATION
If any accessories not sold or authorized by Zimmer GmbH are used, the function of the product cannot be
guaranteed.ZimmerGmbHaccessoriesarespecicallytailoredtotheindividualproducts.
►For optional accessories and those included in the scope of delivery, refer to our website.
9 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 unexpected movements can occur.
►Before commissioning the product and 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.
►Package the product so that it is protected from corrosion.
►Cover the product with a weatherproof, tear-resistant foil to prevent dust.
►Placeadditionaldesiccantunderthelmasnecessary.
►Pack the product and do not expose it to direct sunlight during storage.
►Clean all components. There must be no soiling left on the components.
►Visually inspect all components.
►Remove all foreign substances.
►Apply corrosion protection to the product.
►Seal pneumatic connections with suitable covers.
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

9
10 Installation
WARNING
Risk of death due to unsuitable lifting equipment
►Use suitable lifting equipment for overhead assembly or disassembly of the product if the dead weight of the
product is > 3 kg.
WARNING
Risk of injury caused by inadequate installation materials
The product can tear off from the load due to the use of unsuitable installation materials.
►Use a suitable mounting piece.
►Use suitable mounting screws.
WARNING
Risk of injury due to uncontrolled movements
Risk of injury in case of unexpected movement of the machine or system into which the product is to be installed.
►Switch off the energy supply of the machine before any work.
►Secure the power supply against being switched on unintentionally.
►Check the machine for any residual energy that may be present.
►Make sure that the function of the air relief connections is not impaired by the mounting piece.
CAUTION
Risk of injury due to uncontrolled movements
Risk of injury in the event of uncontrolled movement of the product when the power supply is connected.
►Switch off the power supply to the machine before carrying out any work.
►Secure the power supply against being switched on unintentionally.
►Check the machine for any residual energy that may be present.
NOTICE
►Installationmayonlybecarriedoutbyqualiedpersonnelinaccordancewiththeseinstallationandoperating
instructions.
►Switch off the power supply before any assembly, installation or maintenance work.
►Makesurethatthemountingpieceissu󹱺cientlyrigid.
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

10
►Observe the tightening torque of the mounting screws.
►Verify the permitted load capacity of the required screw connections in accordance with VDI 2230.
INFORMATION
Further installation information:
• The mounting screws are not included in the scope of delivery.
• Strengthclassofthemountingscrewsisatleast12.9(DINENISO4762)
Installation sizes with Ø50-90:
• Mounting screw thread size: M5
• Recommended tightening torque [Nm]: 9.3
Installation sizes with Ø100-160:
• Mounting screw thread size: M6
• Recommended tightening torque [Nm]: 15.7
10.1 Installing the product
WARNING
Risk of injury due to incorrect installation
The disassembly of housing parts decreases the holding torque. If installed incorrectly, there is the possibility of a
complete loss of function.
►During product installation, follow the order listed in the installation and operating instructions.
NOTICE
►The authorized connections that are available can be found in the accessories list on our website. The
necessary ordering information can also be found there.
►Use compressed air in accordance with DIN ISO 8573-1 [4:4:4].
CAUTION
Risk of injury caused by falling parts
Operating pressure that is too high or short-term pressure peaks over the maximum permitted operating pressure
can lead to a fault or the destruction of the product.
The holding torque can decrease.
►Maintain the maximum permitted operating pressure.
►Use a pressure relief valve.
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

11
NOTICE
Requirements for the mounting surface:
• Mounting surface to which the product on the mounting piece may be mounted:
Outside diameter of the product - annular surface diameter
• Permissible unevenness [mm]: 0.05
• Permitted rectangularity to the rotation axis [mm]: 0.02
• Permitted total radial runout of the shaft [mm]: 0.02
3
A
0.02
0.02 A 0.02 A
3Mounting surface
You can install the product from above via the pneumatic connection or from below via the mirrored drilling pattern to the
mounting piece.
INFORMATION
Recommendation
►Use a quick exhaust valve at a distance of < 1000 mm to the product in order to achieve the closing times
speciedinthetechnicaldatasheet.
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

12
10.1.1 Installing the product with energy supply from above
►Clean the mounting surface of the mounting piece with suitable
cleaning materials.
4
5
5
►Remove the top grub screw.
4Top grub screw
5Airreliefconnectionwithlter
►Check the pressure setting and functionality of the pressure relief
valve. 6
►Insertthescrewttingintotheconnectiondesignatedforthis
purpose.
►Apply the corresponding operating pressure to the product.
6Screwtting
►Push the product onto the shaft.
7
8
9
►Position the product on the mounting piece.
►Loosely attach the mounting screws.
►De-aerate the product completely.
ÖThe product centers itself to the shaft.
►Tighten the mounting screws crosswise.
7Mounting screw
8Shaft
9Mounting piece
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

13
10.1.2 Installing the product with energy supply from below
NOTICE
Requirements for the mounting surface:
• Surfaceroughnessonthemountingpiece:≥Ra1.6
4Top grub screw
bl Bottom grub screw 4
bl
►Remove the top grub screw.
bl
4
►Remove the bottom grub screw.
4Top grub screw
bl Bottom grub screw
►Insert the bottom grub screw into the connection from above.
bl
►Turn the grub screw until it reaches the bottom housing half.
bl Bottom grub screw
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

14
►Check the pressure setting and functionality of the pressure relief
valve.
6
►Insertthescrewttingintotheconnectiondesignatedforthis
purpose.
►Apply the corresponding operating pressure to the product.
6Screwtting
►Turn the product.
bm
►Check whether the O-ring is inserted properly at the bottom
connection.
bm O-Ring
►Push the product onto the shaft.
7
8
9
►Position the product on the mounting piece.
►Loosely attach the mounting screws.
►De-aerate the product completely.
ÖThe product centers itself to the shaft.
►Tighten the mounting screws crosswise.
7Mounting screw
8Shaft
9Mounting piece
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

15
►Removethescrewttingfromtheconnection.
6
6Screwtting
►Remove the bottom grub screw.
bl
►Coat the thread of the grub screw with a suitable thread sealant.
►Insert the top grub screw into the connection from above.
►Loosely screw in grub screw until the surface of the product and the
grubscrewareush.
bl Bottom grub screw
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

16
10.2 Installing the sensors
INFORMATION
A sensor can be installed as an option in all installation sizes.
The sensor and the appropriate attachment kit are not included in the scope of delivery.
You can purchase the sensor and the appropriate attachment kit as accessories.
The appropriate attachment kit is required for installing the sensor.
►For information on optional accessories and those included in the scope of delivery, refer to our website.
The appropriate attachment kit is required for installing the sensor.
bn
bo
►Install the attachment kit on the product using the countersunk screw.
bn Attachment kit
bo Countersunk screw
INFORMATION
►Forfurtherinformationoninstallingthemagneticeldsensors,refertothecurrentinstallationandoperating
instructions for the product on our website.
• MFS02-S-KHC-P2-PNP
The sensor is used for piston position sensing.
bp
►Teach both switching points of the sensor
to the Open switch position at an operating
pressure of 5.5 bar.
bp Sensor
10.3 Installing accessories
NOTICE
Before installing an accessory, make sure it is suitable for use with the selected variant.
►Youcanndinformationonourwebsite.
►Please contact Zimmer Customer Service if you have any questions.
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

17
11 Commissioning
CAUTION
Risk of burns from hot surfaces
During operation and commissioning, the surfaces of the product may become hot.
►Keep temperature-sensitive parts away from hot surfaces.
►Do not install any temperature-sensitive parts to a product with hot surfaces.
►Only touch the product while wearing appropriate personal protective equipment.
CAUTION
Risk of injury caused by falling parts
Operating pressure that is too high or short-term pressure peaks over the maximum permitted operating pressure
can lead to a fault or the destruction of the product.
The holding torque can decrease.
►Maintain the maximum permitted operating pressure.
►Use a pressure relief valve.
11.1 Checking operational readiness
WARNING
Risk of injury due to uncontrolled movements
An emergency stop of the complete machine and the accompanying emergency braking of the product can lead
to a decrease of the holding torque. The malfunction resulting from this can lead to injuries.
►After an emergency stop, check the operational readiness of the product.
►Depressurize the product.
►Initiate a torque that corresponds to the maximum holding torque of the product.
►Make sure that the shaft does not warp in this status.
ÖThe clamping surfaces of the product are worn if it is discovered that the shaft is warped.
►Do not put the product into operation again until the operational readiness has been checked successfully.
CAUTION
Risk of injury due to uncontrolled movements
Contact with lubricants can lead to a decrease in the holding torque. The malfunctions resulting from this can
lead to injuries.
►Check the product regularly for lubricants in the clamping area.
►Clean the clamping area if the product comes into contact with lubricants.
►Check the operational readiness of the product if the product comes into contact with lubricants.
►Check all mounting screws for the prescribed tightening torque.
►Check all connections for leaks.
►Check the clamping process by attempting to move the product when power is connected.
►Check that the product moves easily in a deenergized state by moving it manually.
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

18
12 Maintenance
CAUTION
Material damage resulting from blowing out with compressed air
Blowing out the product with compressed air can cause malfunctions and pose a risk of accidents.
►Never purge the product with compressed air.
CAUTION
Material damage caused by liquid and solvent-based cleaners
Liquid and solvent-based cleaning agents can cause malfunctions and pose a risk of accidents.
►Do not clean the product with any cleaning agents that are liquid or contain solvents.
The maintenance interval may be shortened under the following circumstances:
• Dirty environment
• Improperuseandusethatdoesnotcomplywiththepowerspecications.
• Operation with impermissible compressed air
• Permissible temperature range not observed
►Even though the product is maintenance-free as mentioned above, perform a regular visual inspection to check for any
damage or contamination.
ÖDismantling and reassembling the product without authorization may result in complications, as special installation
equipment is required in some cases. Zimmer GmbH accepts no liability for any resulting malfunctions or damage.
13 Decommissioning/disposal
INFORMATION
When the product reaches the end of its operational phase, it can be completely disassembled and disposed of.
►Disconnect the product completely from the power supply.
►Dispose of the components properly according to the material groups.
►Comply with the locally applicable environmental and disposal regulations.
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

19
14 Declaration of Conformity
IntermsoftheEUMachineryDirective2006/42/EC(AnnexII1A)
Name and address of the manufacturer:
Zimmer GmbH
Im Salmenkopf
77866 Rheinau, Germany
[phone]
[email protected]
www.zimmer-group.com



We hereby declare that the products described below
Product designation: Rotary clamping element, pneumatic
Type designation: DKPS1000 series
conforms to the requirements of the 2006/42/EC directive in its design and the version we put on the market.
The following harmonized standards have been used:
DIN EN ISO 12100 Safety of machinery - General principles for design - Risk assessment and risk
reduction
DIN EN ISO 4414 Pneumaticuidpower-Generalrulesandsafetyrequirementsforsystemsandtheir
components
A full list of applied standards can be obtained from the manufacturer.
Michael Hemler Rheinau, Germany, 2022-06-28
Authorized representative for the
compilation of relevant technical
documents
(Placeanddateofissuance) Martin Zimmer
(Legallybindingsignature)
Managing Partner
INSTALLATION AND OPERATING INSTRUCTIONS: DKPS1000
DDOC01621 / a EN / 2022-10-04
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com