Zimmer DVR1000 Series User manual

INSTALLATION AND
OPERATING
INSTRUCTIONS
Rotary distributor
DVR1000 series
DDOC00221
THE KNOW-HOW FACTORY
www.zimmer-group.com

3
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 Forces and torques..............................................................................................................................................................................................................6
5.2 Type plate .............................................................................................................................................................................................................................6
6 Functional description ................................................................................................................................................................. 7
7 Technical data .............................................................................................................................................................................. 8
8 Accessories/scope of delivery ................................................................................................................................................... 8
9 Transportation/storage/preservation......................................................................................................................................... 8
10 Installation .................................................................................................................................................................................... 9
10.1 Installing the product.........................................................................................................................................................................................................10
10.2 Installing the energy supply ..............................................................................................................................................................................................12
10.3 Installing accessories ........................................................................................................................................................................................................12
10.4 Attaching the torque support arm ....................................................................................................................................................................................13
10.4.1 ProbusDVR1125PBpinassignment ...............................................................................................................................................................14
10.4.2 PronetDVR1125PNpinassignment................................................................................................................................................................15
11 Maintenance............................................................................................................................................................................... 16
12 Decommissioning/disposal ...................................................................................................................................................... 16
13 Declaration of Incorporation ..................................................................................................................................................... 17
INSTALLATION AND OPERATING INSTRUCTIONS: DVR1000
DDOC00221 / b EN / 2021-11-11
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

4
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: DVR1000
DDOC00221 / b EN / 2021-11-11
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.
Itisttedtoindustrialmachinesandisusedtohold,transportandstoreworkpieces.
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
• 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.
►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.
►Observethespeciedmaintenanceintervalsandspecicationsregardingthequalityoftheoperatingmaterial.
►When using the product under extreme conditions, adjust the maintenance interval according to the degree of
contamination.
►Note that, due to the spring tension, you should exercise increased caution when uninstalling products with
integrated springs.
INSTALLATION AND OPERATING INSTRUCTIONS: DVR1000
DDOC00221 / b EN / 2021-11-11
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 for forwarding electric and pneumatic energies through rotating connections.
The product is designed exclusively for pneumatic operation.
Direct contact with perishable goods/food is not permitted.
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
5.1 Forces and torques
INFORMATION
►Youcanndtheinformationinthetechnicaldatasheetonourwebsite.
►Please contact Zimmer Customer Service if you have any questions.
5.2 Type plate
A type plate is attached to the housing of the product. XXX
XX-XXXXXX
am
an
Thearticlenumberandconrmationnumberareshownonthetype
plate.
am Article number
an Conrmationnumber
INSTALLATION AND OPERATING INSTRUCTIONS: DVR1000
DDOC00221 / b EN / 2021-11-11
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

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6 Functional description
Theproductsaredesignedtobemediaexchangers.Allcurrentsfromnecurrentsupto250Vandamaximumof9Acan
be transmitted reliably.
The housing acts as a stator by means of the torque support arm. The energy/media to be transferred is brought in here.
The compact design reduces the torque loads for the handling system to a minimum. Inside, the contacts on the slip ring
allowforhighexibilityinelectricaltransmission.
The product avoids interference contours and thus prevents cable breaks, damage or tears caused by exposed wires.
Therobotangeandtheconnectingangeonthetoolaretherotatingelements.
ThestructuraldesignoftherobotangeisbasedonthespecicationsfromDINENISO9409-1.
1Case
2Torque support
3Hoseless air connection to the tool
changer
4Robotange
5Energy and data transmission
68x pneumatic feed-through
7Assembly window
8Toolange
2
3
1
4
5
5
3
6
6
8
2
7
6
INSTALLATION AND OPERATING INSTRUCTIONS: DVR1000
DDOC00221 / b EN / 2021-11-11
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

8
7 Technical data
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.
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.
►Cover the product with a weatherproof, tear-resistant foil to prevent dust.
►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.
►Properly remove potential corrosion spots.
►Close electrical connections using suitable covers.
INSTALLATION AND OPERATING INSTRUCTIONS: DVR1000
DDOC00221 / b EN / 2021-11-11
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

9
10 Installation
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.
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 unintentional switch-on.
►Check the machine for any residual energy.
►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.
INFORMATION
• Strength class of the mounting screws 8.8 (DIN EN ISO 4762)
►Observe the tightening torque of the mounting screws.
INSTALLATION AND OPERATING INSTRUCTIONS: DVR1000
DDOC00221 / b EN / 2021-11-11
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

10
10.1 Installing the product
INFORMATION
Whenselectingtheinstallationsizeanddesignoftheproduct,thetypeofconnectingangeontherobotin
accordancewithENISO9409-1andthefunctionstobeimplementedonthetoolarethedecidingfactors.
Theproductisinstalledbetweentherobotangeandthetool.Installationbeginsontherobotange.Thetoolortool
changer can then be installed on the product.
►Open the cover of the assembly window.
bl
bm
7
9
►Place the product with the centering device onto the mating part on
the robot arm.
►Pay attention to the position of the straight pin.
►Screw the mounting screws in crosswise.
►Turn the assembly window gradually over the respective screw
position.
►Close the cover of the assembly window.
7Assembly window
9Centering
bl Mounting screw
bm Straight pins
INSTALLATION AND OPERATING INSTRUCTIONS: DVR1000
DDOC00221 / b EN / 2021-11-11
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

11
►Insert a straight pin into the drilled hole.
bn
bo
►Use the straight pin and the centering device to position the tool on
thetoolange.
►Usethemountingscrewstomountthetoolonthetoolange.
bn Straight pins
bo Mounting screw
INSTALLATION AND OPERATING INSTRUCTIONS: DVR1000
DDOC00221 / b EN / 2021-11-11
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

12
10.2 Installing the energy supply
INFORMATION
Eight integrated air transmitters are provided.
►Insertthescrewttingsintotheprovidedconnections.
bp
3
bq
In addition, there is the option of a hoseless pneumatic feed-through to
thefrontofthetoolange.Ifthisconnectionisused,theoutputsonthe
outeredgeofthetoolangemustbesealed.
Theassignmentoftheinputsandoutputscanbeidentiedby
numbering.
3Hoseless air connection to the tool changer
bp Outer edge of housing
Robot input
bq Outeredgeoftoolange
Tool output
NOTICE
►Close off unused connections using suitable dummy plugs.
►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 [2:4:1].
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: DVR1000
DDOC00221 / b EN / 2021-11-11
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

13
10.4 Attaching the torque support arm
NOTICE
Non-compliance may result in material damage.
Thetorquesupportarmisdesignedsothatlateraltorquesarenotappliedtothemiddlepartwithoatingbearing.
►Implement the torque support arm as shown.
Exchangingthestandardtorquesupportarmfora2-pointscrewttinginthemiddlepartmaydamagetheseals
and the inner electric slip ring system.
INFORMATION
ThepinmustbemanufacturedaccordingtoDINISO2768-1,Table1"Generaltolerancesforlength
measurements."
►Aim for manufacturing at the lower tolerance limit.
►Calculate the pin diameter for the torque support arm using the dimensions from the dimensional drawing on
the data sheet.
34
2x 22
115
►Arrange the pin of the torque support arm parallel to the turning axis
or casing surface of the product.
►Maintain a parallelism tolerance of 0.1 mm.
A
0.1 A
►Donotpositionthexedpointofthetorquesupportarmontothe
product.
INSTALLATION AND OPERATING INSTRUCTIONS: DVR1000
DDOC00221 / b EN / 2021-11-11
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

14
10.4.1 Probus DVR1125PB pin assignment
DANGER
Potentially life-threatening hazard due to electrical voltage
►Supply the power only via the plug side.
►Make sure that the current is not applied to the plug side when the plug is disconnected.
5
4
3
2
1
6
PE
4 3
1 2
5
M17 7-pin pin M125-pinB-codedpin
Power supply
Color Function
PE GNYE
green/yellow
Ground
1
2
3
4
5 unassigned
6 unassigned
Probus
SHIELD Shielding
1 unassigned
2 WH
white
Probus
3 unassigned
4BK
black
Probus
5 unassigned
M17 7-pin socket M125-pinB-codedsocket
1
2
3
4
5
6
PE
43
12
5
INSTALLATION AND OPERATING INSTRUCTIONS: DVR1000
DDOC00221 / b EN / 2021-11-11
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

15
10.4.2 Pronet DVR1125PN pin assignment
DANGER
Potentially life-threatening hazard due to electrical voltage
►Supply the power only via the plug side.
►Make sure that the current is not applied to the plug side when the plug is disconnected.
5
4
3
2
1
6
PE
2
3
1
4
M17 7-pin pin M12 4-pin D-coded socket
Power supply
Color Function
PE GN
green
Ground
1
2
3
4
5 unassigned
6 unassigned
Pronet
SHIELD Shielding
1 GN
green
Ethernet
2 OG
orange
Ethernet
3 WHGN
white/green
Ethernet
4 WHOG
white/orange
Ethernet
M17 7-pin socket M12 4-pin D-coded socket
1
2
3
4
5
6
PE
2
3
1
4
INSTALLATION AND OPERATING INSTRUCTIONS: DVR1000
DDOC00221 / b EN / 2021-11-11
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

16
11 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.
INFORMATION
Non-compliance may result in material damage.
If the product is constantly subjected to an alternating direction of rotation, the maximum number of rotations will
no longer be reached.
The actual service life depends on the following factors:
• Speed
• Changes in direction of rotation
• Environmental conditions (humidity, temperature)
• Handling weight
• Electrical voltage and amperage
• Continuous operation with sealing air and its quality
Maintenance-free operation of the product is guaranteed for up to 10 million cycles.
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.
• Ambient temperature is too high.
►Even though the product is maintenance-free as mentioned above, perform a regular visual inspection to check for any
corrosion, damage or contamination.
►Have maintenance work be performed by Zimmer Customer Service whenever possible.
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.
12 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: DVR1000
DDOC00221 / b EN / 2021-11-11
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

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13 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
77866 Rheinau, Germany
[phone]
[email protected]
www.zimmer-group.com



We hereby declare that the incomplete machine described below
Product designation: Rotary distributor
Type designation: DVR1000 series
conform to the requirements of the Machinery Directive, 2006/42/EC, Article 2g, Annex VII.b – Annex II.b, in its design and
the version we put on the market.
Basichealthandsafetyrequirements:
Nr. 1.1.2, Nr. 1.1.3, Nr. 1.1.5, Nr. 1.3.1, Nr. 1.3.2, Nr. 1.3.4, Nr. 1.3.7, Nr. 1.5.1, Nr. 1.5.3, Nr. 1.5.4, Nr. 1.6.4, Nr. 1.7.1, Nr.
1.7.3.
A full list of applied standards can be obtained from the manufacturer.
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 it has been ascertained, if applicable, that the machine or
system in which the incomplete machine is to be installed satises 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.
Kurt Ross Rheinau, Germany, 2019-10-15
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: DVR1000
DDOC00221 / b EN / 2021-11-11
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com