Zimmer GEP5000IL Series User manual

www.zimmer-group.com
INSTALLATION
AND OPERATING
INSTRUCTIONS
2-jaw parallel gripper
3-jaw concentric gripper
GEP5000IL/GED5000IL series
DDOC00211
THE KNOW-HOW FACTORY

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Parameter explanation (glossary)
Parameters Explanation
ControlWord
The gripper is controlled using the "ControlWord."
The "ControlWord" is bit-exclusive, which means that only one bit at a time can be active in the
"Word." The value "NULL" is also permitted.
DeviceMode The "DeviceMode" is used to select gripping proles as well as the additional help modes in the
gripper.
Workpiece No. You can use this parameter to select or save the workpiece recipes stored in the gripper.
TeachPosition The "TeachPosition" is the actual workpiece position.
WorkPosition The "WorkPosition" is the inner jaw position on the gripper. Depending on the application, for
example with internal grippers, this can also be the standby position.
GripForce The "GripForce" parameter is used to congure the gripping force.
PositionTolerance This is the tolerance window for the "TeachPosition," "BasePosition" and "WorkPosition." The
value of the parameter acts in both directions.
BasePosition The "BasePosition" is the outer "JawPosition." Depending on the gripper prole, this can also
be a work position!
ShiftPosition The "ShiftPosition" is a switching position between pre-positioning and gripper movement.
StatusWord In its bits, the "StatusWord" returns the most important information about the status of the
gripper to the control system.
Diagnosis If an error should occur, the "Diagnosis" outputs a diagnostic code that can be compared with
the error list.
ActualPosition The value of the current position of the gripper [1/100 mm].
Error Fault, error message
DIR Direction/24V cable connection – Depending on the gripper, this signal is used to move the
gripper.
Teach/Adjust
Program/Congure
Using this signal, depending on the gripper type, the current position of the gripper jaws can be
taught in as the new workpiece position. "Adjust" is used as a command to dene the reachable
end positions of the gripper jaws.
GND Abbreviation for ground connection
Offset Correction value
Traversing routine Dened procedure for movement of the gripper jaws
Travel path Path on which the gripper jaws travel

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INSTALLATION AND OPERATING IN-
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Contents
1 Supporting documents......................................................................................................................................................... 5
1.1 Notices and graphics in the installation and operating instructions.......................................................................................................................5
2 Safety notices ........................................................................................................................................................................ 6
3 Proper use ............................................................................................................................................................................. 7
4 Personnel qualication ......................................................................................................................................................... 7
5 Product description .............................................................................................................................................................. 8
5.1 Possible applications ..................................................................................................................................................................................................8
5.2 Forces and torques .....................................................................................................................................................................................................8
5.3 Type plate.....................................................................................................................................................................................................................8
6 Function ................................................................................................................................................................................. 9
6.1 LED display ................................................................................................................................................................................................................10
6.1.1 LED display for statuses GEP/GED5000IO...............................................................................................................................................10
6.1.2 LED display for gripper positions GEP/GED5000IO................................................................................................................................10
6.1.3 LED display GEP/GED5000IL ....................................................................................................................................................................11
6.2 Electrical specications ............................................................................................................................................................................................11
6.3 Control........................................................................................................................................................................................................................11
6.4 Veried conguration examples...............................................................................................................................................................................11
6.5 Self-locking mechanism............................................................................................................................................................................................11
6.6 Protection class .........................................................................................................................................................................................................11
6.7 Technical data............................................................................................................................................................................................................11
6.8 Minimum travel path of the "Digital" GEP/GED5000IO and "IO-Link" GEP/GED5000IL .....................................................................................12
6.8.1 Movement prole of the travel of the gripper toward the "WorkPosition" (outside gripping)................................................................12
6.8.2 Movement prole of the travel of the gripper toward the "BasePosition" (inside gripping) ..................................................................13
7 Installation............................................................................................................................................................................ 14
7.1 General installation information ...............................................................................................................................................................................14
7.2 Installing the mechanical system .............................................................................................................................................................................15
7.2.1 Installing GEP5000IL ..................................................................................................................................................................................15
7.2.2 Installing GED5000IL ..................................................................................................................................................................................16
7.3 Installing the power supply.......................................................................................................................................................................................17
7.4 Installing the power supply GEP5000IL-00/GED5000IL-00...................................................................................................................................18
7.4.1 Installing the wiring .....................................................................................................................................................................................18
7.5 Installing the power supply GEP5000IO-00/GED5000IO-00 .................................................................................................................................19
7.5.1 Installing the wiring .....................................................................................................................................................................................19
7.6 Static charge..............................................................................................................................................................................................................20
7.7 Heat dissipation.........................................................................................................................................................................................................20
7.8 Installing accessories................................................................................................................................................................................................20
8 Commissioning ................................................................................................................................................................... 21
8.1 Commissioning for GEP5000IO-00/GED5000IO-00...............................................................................................................................................21
8.1.1 Switching sequence....................................................................................................................................................................................21
8.1.2 Teaching in "TeachPosition".......................................................................................................................................................................22
8.1.3 Teaching in the end positions ....................................................................................................................................................................22
8.2 Commissioning for GEP5000IL-00/GED5000IL-00 ................................................................................................................................................23
8.2.1 Process data................................................................................................................................................................................................23
8.2.2 IODD import.................................................................................................................................................................................................24
8.3 "Handshake" data transfer method..........................................................................................................................................................................24
8.4 Parameters.................................................................................................................................................................................................................25
8.4.1 "ControlWord" parameter ...........................................................................................................................................................................25
8.4.2 "DeviceMode" parameter............................................................................................................................................................................27
8.4.3 "WorkpieceNo" parameter..........................................................................................................................................................................28
8.4.4 "PositionTolerance" parameter...................................................................................................................................................................28

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8.4.5 "GripForce" parameter................................................................................................................................................................................29
8.4.6 "TeachPosition" parameter .........................................................................................................................................................................29
8.4.7 "StatusWord" parameter .............................................................................................................................................................................30
8.4.8 "Diagnosis" parameter ................................................................................................................................................................................31
8.4.9 "ActualPosition" parameter.........................................................................................................................................................................31
8.5 "Cold start".................................................................................................................................................................................................................32
8.6 "Easy Startup"............................................................................................................................................................................................................32
8.6.1 "Easy Startup"..............................................................................................................................................................................................33
8.7 Starting gripping movement.....................................................................................................................................................................................34
8.8 Repeated movement in the same direction ............................................................................................................................................................34
8.8.1 "Save recipe" ...............................................................................................................................................................................................35
8.9 Recipe examples "Load recipe" ...............................................................................................................................................................................36
9 Operation............................................................................................................................................................................. 37
9.1 Menu structure for GEP5000IO/GED5000IO..........................................................................................................................................................37
9.2 Menu cycle course of action for GEP5000IO/GED5000IO....................................................................................................................................38
9.3 Menu function for GEP5000IO/GED5000IO ...........................................................................................................................................................38
9.4 Menu settings for GEP5000IO/GED5000IO............................................................................................................................................................39
9.4.1 Menu 1: Force setting.................................................................................................................................................................................39
9.4.2 Menu 2: Teach area "Width".......................................................................................................................................................................40
9.4.3 Menu 3: "Gripper mode".............................................................................................................................................................................40
9.4.4 Menu 4: Teach area "Position“...................................................................................................................................................................40
9.5 Menu functions for GEP5000IL/GED5000IL...........................................................................................................................................................40
10 Gripping force charts.......................................................................................................................................................... 40
11 Error diagnosis .................................................................................................................................................................... 41
11.1 Troubleshooting display for GEP5000IL/GED5000IL.............................................................................................................................................41
11.2 Troubleshooting display for GEP5000IO/GED5000IO ...........................................................................................................................................43
12 Table with acyclic data (ISDU)............................................................................................................................................ 45
13 Maintenance........................................................................................................................................................................46
13.1 Safety notice ..............................................................................................................................................................................................................46
14 Accessories/scope of delivery........................................................................................................................................... 47
15 Transportation/storage/preservation ................................................................................................................................ 47
16 Decommissioning/disposal ............................................................................................................................................... 47
17 RoHS declaration................................................................................................................................................................ 48
18 REACH declaration ............................................................................................................................................................. 48
19 Declaration of Incorporation .............................................................................................................................................. 49
20 Declaration of Conformity .................................................................................................................................................. 50

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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
They must be read and understood by all persons who work with or handle the product during any phase of the
product life time.
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 the 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
The individual hazard levels, notices and warnings are marked with signal words.
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.

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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 mounted to industrial machines and is used to hold tools.
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 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.
Modications to the product, such as adding drilled holes or threads, may be made only with prior approval from
Zimmer GmbH.
The specied 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!
Notes and handling regulations for electrostatically sensitive components
Electrostatically sensitive components are individual components, integrated circuits or assemblies that can be
damaged by electrostatic elds or electrostatic discharge.
ÖWhen handling electrostatic components, make sure that persons, the work area and packaging are all fully
grounded!
ÖElectronic components may only be touched by persons in appropriately identied areas with conductive
ooring and only if:
• These persons are grounded by means of special bracelets.
• These persons wear shoes that are suitable and approved for the discharge of electrostatic charges.
ÖElectronic assemblies must not be brought into contact with plastics and parts of clothing that have plastic
content.
ÖElectronic assemblies may only be stored on conductive underlays.
ÖElectronic assemblies must not be installed in the vicinity of data back-up devices or monitors (monitor
distance > 100 mm).
ÖMeasurements may only be performed on electronic assemblies if:
• The measuring instrument is grounded (e.g. via a ground conductor)
• The measuring head is momentarily discharged before measuring with a oating measuring instrument.

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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 electric operation using a 24V DC power supply.
The product must always be mounted on materials that dissipate heat.
The product is to be used as intended in enclosed rooms for temporary gripping, handling and holding.
The product is not suitable for clamping workpieces during a machining process.
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.

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5 Product description
CAUTION
Reduction of gripping force
When exible components are gripped, the gripping force of the product is reduced.
A reduced gripping force can lead to personal injury or material damage, because the components that are
being gripped can no longer be securely gripped and transported.
NOTICE
To ensure that the gripper jaws do not get deformed, make sure that the conguration of the gripping force and
the selection of the gripper nger length is correct.
An incorrect conguration or selection can lead to malfunction.
The product is a secure quick-change system in accordance with DIN ISO 13849-1. The basic and proven safety principles
from DIN EN 13849-1 can be complied with only if original parts from Zimmer GmbH are used.
5.1 Possible applications
Outside gripping
The product can be used for outside gripping.
Inside gripping
The product can be used for inside gripping.
5.2 Forces and torques
INFORMATION
For information on the forces and torques for the following product, please refer to our website at www.
zimmer-group.com:
• GEP5000IL series (technical data sheet)
• GED5000IL series (technical data sheet)
Please contact Zimmer Customer Service if you have any questions.
5.3 Type plate
A type plate is attached to the housing of the product.
The part number am and the serial number an are shown on the type plate. XXX
XX-XXXXXX
am
an

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6 Function
The gripper ngers of the parallel gripper are arranged parallel to each other on two opposing guide rails and can be moved
relative to each other. The power of the motor is converted into a linear movement by means of a wedge hook transmission
and is thereby transferred to the gripper jaws.
Despite its small installation space, the gripper is suited for the gripping of a wide range of form t and frictional t parts.
1Double-lip seal 6Gripper jaws
2Guide rail 7Positive-drive wedge hook transmission
3Integrated control module 8Mounting and positioning
4Power supply 9BLDC motor
5Removable centering sleeve
Cutaway view of the GED5000IL Cutaway view of the GEP5000IL

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6.1 LED display
6.1.1 LED display for GEP/GED5000IO statuses
cl Power/communication cp Plus button
Increase parameter value
cm Error cq Set button
cn Position display/menu cr Minus button
Decrease parameter value
co Parameter display
Binary error code display
cp
cl
cm
co
cq
cr
cn
6.1.2 LED display for GEP/GED5000IO gripper positions
Gripper is at base position ("BasePosition")
Open gripper jaws
cn
Gripper is at workpiece position ("TeachPosition")
Gripper is at work position ("WorkPosition")
Gripper is at the taught in "TeachPosition"
Both of the two LEDs light up

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6.1.3 LED display GEP/GED5000IL
INFORMATION
In the IO-Link variants, only the LED display has a function. None of the buttons have a function. All congu-
rations of the functions and settings are made via the control system.
Please contact Zimmer Customer Service if you have any questions.
6.2 Electrical specications
INFORMATION
For electrical specications, please refer to our website at www.zimmer-group.com.
This data varies within the series, depending on the specic design.
Please contact Zimmer Customer Service if you have any questions.
6.3 Control
INFORMATION
For information on the control, please refer to our website at www.zimmer-group.com.
Please contact Zimmer Customer Service if you have any questions.
6.4 Veried conguration examples
INFORMATION
For information on veried conguration examples, please refer to our website at
www.zimmer-group.com.
• GEP5000IL series (technical data sheet)
• GED5000IL series (technical data sheet)
Please contact Zimmer Customer Service if you have any questions.
6.5 Self-locking mechanism
INFORMATION
The product has a mechanical self-locking mechanism to ensure that the workpiece remains held by the product
in the event of power supply loss or failure (e.g. an emergency stop).
Please contact Zimmer Customer Service if you have any questions.
6.6 Protection class
NOTICE
The product achieves protection class IP40 in all mounted positions of installation.
6.7 Technical data
INFORMATION
For technical data, refer to our website at www.zimmer-group.com.
This data varies within the series, depending on the specic design.
Please contact Zimmer Customer Service if you have any questions.

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6.8 Minimum travel path of the "Digital" GEP/GED5000IO and "IO-Link" GEP/GED5000IL
The gripper requires a minimum travel path of > 1.25 mm per gripper jaw before it is permitted to make contact with a
workpiece.
ÖIf the gripper makes contact with the workpiece earlier than this value, the gripper cannot establish the desired gripping
force and displays an error.
The minimum travel path applies to both directions of movement and is independent of the starting position of the gripper
jaws.
This minimum travel path depends on:
• The desired gripping force
• The dimensions of the gripper ngers
Installation size Minimum travel path
GEP/GED5006IO/IL 1.25 mm per gripper jaw
GEP/GED5008IO/IL 1.25 mm per gripper jaw
GEP/GED5010IO/IL 1.25 mm per gripper jaw
Then the gripper moves slightly past the front and rear end position.
This area is not taken into account in the respective position specication.
This means that the value of the corresponding end position is displayed.
The active positions of the gripper are displayed by the LED display on the gripper.
6.8.1 Movement prole of the travel of the gripper toward the "WorkPosition" (outside gripping)
Greifrichtung
BasePosition [1/100 mm] WorkPosition [1/100 mm]
TeachPosition
PositionTolerance
Anfahrtsweg
>1,25 mm +/- 0,2 mm
je Backe
verbotener
Greifbereich
Toleranz Toleranz
Endlagenerkennung
0,5 mm +/- 0,2 mm
empfohlener Greifbereich
Installation size Recommended working stroke
GEP/GED5006IO/IL 12 mm - end position - travel distance = 8.60 mm
GEP/GED5008IO/IL 16 mm - end position - travel distance = 12,60 mm
GEP/GED5010IO/IL 20 mm - end position - travel distance = 16,60 mm

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6.8.2 Movement prole of the travel of the gripper toward the "BasePosition" (inside gripping)
Greifrichtung
BasePosition [1/100 mm] WorkPosition [1/100 mm]
TeachPosition
PositionTolerance
Anfahrtsweg
>1,25 mm +/- 0,2 mm
je Backe
verbotener
Greifbereich
Toleranz Toleranz
Endlagenerkennung
0,5 mm +/- 0,2 mm
empfohlener Greifbereich
Installation size Recommended working stroke
GEP/GED5006IO/IL 12 mm - end position - travel distance = 8.60 mm
GEP/GED5008IO/IL 16 mm - end position - travel distance = 12,60 mm
GEP/GED5010IO/IL 20 mm - end position - travel distance = 16,60 mm

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7 Installation
7.1 General installation information
WARNING
Risk of injury due to uncontrolled movement
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 machine against being switched on unintentionally.
►Check the machine for any residual energy that may be present.
CAUTION
Risk of injury due to uncontrolled movement
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 product for any residual energy that may be present.
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 specications.
ÖPermissible unevenness: 0.03 mm
• The mounting screws are not included in the scope of delivery.
• Strength class of the mounting screws ≥ 8.8 (DIN EN ISO 4762)
• Observe the tightening torque of the mounting screws.
ÖZimmer GmbH recommends verifying the permitted load-carrying capacity of the required screw connections in
accordance with VDI 2230.
• The exact installation positions can be found on the technical data sheet on our website.

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7.2 Installing the mechanical system
7.2.1 Installing GEP5000IL
The product can be installed with its base or side on
the mounting piece.
The following work steps must be observed during
installation:
►Insert the centering sleeves bm into the
designated ts on the gripper.
►Position the gripper on the designated mounting
piece using the centering sleeves bm.
►Use the mounting screws bl to secure the
gripper to the mounting piece.
bm
bl
bm
bm

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7.2.2 Installing GED5000IL
The product can be installed with its base or side on
the mounting piece.
The following work steps must be observed during
installation:
►Insert the mounting pins bm into the designated
ts on the gripper.
►Position the gripper on the designated mounting
piece using the mounting pins bm.
►Use the mounting screws bl to secure the
gripper to the mounting piece.
bl
bm
bl

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7.3 Installing the power supply
Observe the following work steps:
►Connect the power supply cable.
ÖYou can nd the corresponding supply cables
on our website.
NOTICE
The cables that are used by Zimmer GmbH feature a minimum bending radius of 10 x the outer diameter.
This bending radius must not be undershot!
►Freely suspended cables must be secured to prevent excessive motion loads or pinching.

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7.4 Installing the power supply for GEP5000IL-00/GED5000IL-00
7.4.1 Installing the wiring
Pin Color Function Explanation
3
21
45
1Brown + 24 V DC sensor Power supply for IO-Link communication
2White + 24 V DC
actuator Actuator supply voltage
3Blue GND sensor 0 V DC sensor supply voltage
4Black C/Q IO-Link communication
5Gray GND actuator 0 V DC actuator supply voltage
The following steps must be carried out for commissioning or installing the product with IO-Link:
►Connect the product to the IO-Link master.
►Secure the voltage supply.

Zimmer GmbH •Am Glockenloch 2 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com 19
INSTALLATION AND OPERATING IN-
STRUCTIONS:
GEP5000/GED5000 electric gripper series
EN / 05/01/2021DDOC00211/i
7.5 Installing the power supply for GEP5000IO-00/GED5000IO-00
7.5.1 Installing the wiring
Pin Color Function Explanation
4
21
68
7
5
3
1White DIR Input, control input, open/close gripper, 24 V
DC
2Brown WorkPosition Output, "gripper in work position" message
3Green Error Output, "error" message
4Yellow TeachPosition Output, "Gripper in programming position"
message
5Gray BasePosition Output, "Gripper in base position" message
6Pink + 24 V DC Supply voltage 24 V DC/5 A
7Blue Teach/Adjust Input, control input, program/adjust workpiece
8Red GND 0V DC supply voltage
dl Gripper
dm Internal sensors, gripper position sensing
dn External control and programming unit
1
2
3
4
5
6
7
8GND
24 V DC
dl dm dn
The following steps must be carried out for commissioning or installing the "Digital" gripper:
►Connect the gripper to the voltage supply.
►Secure the voltage supply.
ÖA voltage supply between PIN 6 and PIN 8 is necessary for operation.
ÖA jaw movement is actuated by a 24 V signal to PIN 1.

Zimmer GmbH •Am Glockenloch 2 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
20
INSTALLATION AND OPERATING IN-
STRUCTIONS:
GEP5000/GED5000 electric gripper series
EN / 05/01/2021DDOC00211/i
7.6 Static charge
NOTICE
Non-compliance may result in material damage.
Grounding the product mount / gripper jaws is recommended if ESD-sensitive parts come into contact with the
product.
Grounding is also recommended in applications that require high EMC shielding.
The movement of the gripper jaws creates low voltages as a result of static charging. These charges cannot be dissipated if
the product is mounted on an insulating surface and if discharge is also not possible through the workpiece.
7.7 Heat dissipation
In the event of high ambient temperatures, the gripper must be installed on heat-dissipating materials.
If the gripper is operated under very high ambient temperatures and with fast clock cycles on an ongoing basis, this might
reduce its service life.
7.8 Installing accessories
NOTICE
Before installing an accessory, make sure it is suitable for use with the selected variant.
Please contact Zimmer Customer Service if you have any questions.