Zimmer GEP5000IL Series User manual

INSTALLATION
AND OPERATING
INSTRUCTIONS
GEP5000IL/GED5000IL series
Gripper, electric
DDOC00211
THE KNOW-HOW FACTORY
www.zimmer-group.com

2
DDOC00211 / h EN / 2020-08-15
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
Parameter explanation (glossary)
Parameter Explanation
ControlWord
The gripper is controlled with the "ControlWord."
The "ControlWord" is bit-exclusive, which means that only one bit at a time can be
active in the "Word." The value "ZERO" 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 applica-
tion, 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 "WorkPosi-
tion." 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 move-
ment.
StatusWord In its bits, the "StatusWord" returns the most important information about the status of
the gripper to the control.
Diagnosis If an error should occur, the "Diagnosis" outputs a diagnostic code that can be com-
pared with the error list.
ActualPosition The value of the current position of the gripper [1/100 mm].
Error Fault, error message
DIR Direction/24V 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
Oset Correction value
Traversing routine Dened procedure for movement of the gripper jaws
Travel path Path on which the gripper jaws travel

INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
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DDOC00211 / hEN / 2020-08-15
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
Contents
1. Supporting documents.......................................................................................................................................................5
2. Safety notes .........................................................................................................................................................................5
1. Proper use............................................................................................................................................................................6
2. Personnel qualication .......................................................................................................................................................6
3. Product description.............................................................................................................................................................7
3.1 Possible applications .......................................................................................................................................................................................7
3.2 Forces and torques...........................................................................................................................................................................................7
3.3 Type plate ..........................................................................................................................................................................................................7
1. Function ...............................................................................................................................................................................8
1.1 Electrical specications....................................................................................................................................................................................8
1.2 LED display........................................................................................................................................................................................................9
1.2.1 LED display for GEP/GED5000IO statuses..................................................................................................................................................... 9
1.2.2 LED display for GEP/GED5000IO gripper positions...................................................................................................................................... 9
1.1.1 LED display GEP/GED5000IL........................................................................................................................................................................10
1.1 Veried conguration......................................................................................................................................................................................10
1.2 Protection classes...........................................................................................................................................................................................10
1.3 Technical data .................................................................................................................................................................................................10
1.4 Self locking mechanism .................................................................................................................................................................................10
1.5 Minimum travel path of the “Digital” GEP/GED5000IO and “IO-Link” GEP/GED5000IL .........................................................................10
1.5.1 Movement prole of the travel of the gripper toward the “WorkPosition” (outside gripping)...................................................................11
1.5.2 Movement prole of the travel of the gripper toward the “BasePosition” (inside gripping)......................................................................11
1. Installation..........................................................................................................................................................................12
1.1 Safety notes.....................................................................................................................................................................................................12
1.2 Installing the mechanical system...................................................................................................................................................................12
1.2.1 Installing the GEP5000 ..................................................................................................................................................................................12
1.2.2 Installing the GED5000 ..................................................................................................................................................................................13
1.3 Installing the electrical system .......................................................................................................................................................................13
1.3.1 Installing the wiring .........................................................................................................................................................................................13
1.1.1 Installing the GEP/GED5000IL “IO-Link” ......................................................................................................................................................14
1.1.2 Installing the GEP/GED5000IO “Digital”.......................................................................................................................................................14
1.1 Static charging ................................................................................................................................................................................................16
1.2 Heat dissipation...............................................................................................................................................................................................16
1.3 Installing accessories .....................................................................................................................................................................................16
1. Commissioning..................................................................................................................................................................17
1.1 Commissioning the GEP/GED5000IO “Digital” ...........................................................................................................................................17
1.1.1 “Digital” switching sequence .........................................................................................................................................................................17
1.1.1 Teaching-in the "TeachPosition" ....................................................................................................................................................................18
1.1.2 Teaching-in the end positions ........................................................................................................................................................................18
1.1 Commissioning the GEP/GED5000IL “IO-Link”...........................................................................................................................................19
1.1.1 Process data....................................................................................................................................................................................................19
1.1.1 IODD import ....................................................................................................................................................................................................20
1.1 "Handshake" data transfer method................................................................................................................................................................20
1.2 Parameter ........................................................................................................................................................................................................21
1.2.1 "ControlWord" parameter ...............................................................................................................................................................................21
1.1.1 "DeviceMode" parameter................................................................................................................................................................................22
1.1.2 "WorkpieceNo" parameter..............................................................................................................................................................................22
1.1.3 "PositionTolerance" parameter.......................................................................................................................................................................23
1.1.4 “GripForce” parameter ...................................................................................................................................................................................23
1.1.1 "TeachPosition" parameter .............................................................................................................................................................................24
1.1.2 "StatusWord" parameter.................................................................................................................................................................................24
1.1.1 “ActualPosition” parameter ............................................................................................................................................................................26
1.1 "Cold boot" ......................................................................................................................................................................................................26
1.2 “Easy Startup”.................................................................................................................................................................................................26

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DDOC00211 / h EN / 2020-08-15
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
1.2.1 “Easy Startup” example code GEP/GED5000IL series...............................................................................................................................27
1.1 Starting gripping movement ..........................................................................................................................................................................28
1.2 "Save recipe" ...................................................................................................................................................................................................28
1.3 Recipe examples "Load recipe".....................................................................................................................................................................29
1. Operation ...........................................................................................................................................................................30
1.1 GEP/GED5000IO menu structure .................................................................................................................................................................30
1.2 GEP/GED5000IO menu cycle procedure .....................................................................................................................................................31
1.1 GEP/GED5000IO menu functions.................................................................................................................................................................32
1.2 GEP/GED5000IO menu settings ...................................................................................................................................................................32
1.2.1 Menu 1: Force setting.....................................................................................................................................................................................32
1.2.2 Menu 2: "Width" teach area............................................................................................................................................................................33
1.2.3 Menu 3: Gripper mode ...................................................................................................................................................................................33
1.2.4 Menu 4: "Position" teach area........................................................................................................................................................................33
1.3 GEP/GED5000IL menu functions..................................................................................................................................................................33
1. Gripping force charts ........................................................................................................................................................33
1. Error diagnosis ..................................................................................................................................................................34
1.1 GEP/GED5000IL error diagnosis...................................................................................................................................................................34
1.1 GEP/GED5000IO error diagnosis..................................................................................................................................................................36
1. Table with acyclical data (ISDU).......................................................................................................................................38
2. Maintenance ......................................................................................................................................................................39
3. Accessories/scope of delivery .........................................................................................................................................39
4. Transportation/storage/preservation ..............................................................................................................................39
5. Decommissioning and disposal.......................................................................................................................................39
1. RoHS declaration (if required)..........................................................................................................................................40
2. REACH declaration (if required).......................................................................................................................................40
3. Declaration of Incorporation.............................................................................................................................................41
1. Declaration of Conformity.................................................................................................................................................42

INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
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DDOC00211 / hEN / 2020-08-15
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
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 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).
Only those documents currently available on the website are valid.
• Catalogs, drawings, CAD data, performance data
• Information on accessories
• Detailed installation and operating instructions
• Technical data sheets
• General Terms and Conditions of Business, including warranty information
2. Safety notes
CAUTION:
Non-compliance may result in severe injuries!
1. Installation, commissioning, maintenance and repairs may only be performed by qualied specialists
in accordance with these installation and operating instructions.
2. The gripper is state-of-the-art. It is tted to industrial machines and is used to hold workpieces. The
following are examples of situations in which the gripper may pose a hazard:
• The gripper is not properly tted, used or maintained
• The gripper module is not used for its intended purpose
• Local regulations (legislation, ordinances, guidelines), such as the EC Machinery Directive, acci-
dent prevention regulations and the installation and operating instructions, are not observed.
3. The gripper may be used only in accordance with its proper use and technical data. Zimmer GmbH
shall accept no liability for any damage caused by improper use.
4. Any use other than the intended use requires written approval from Zimmer GmbH.
5. Make sure that the power cables are disconnected before you install, modify, maintain or repair the
gripper.
6. In case of maintenance, modication or attachment work, remove the gripper from the machine and
perform the work outside the danger zone.
7. When commissioning or testing, make sure that the gripper cannot be activated by mistake.
8. Modications to the gripper, such as adding drilled holes or threads, may be made only with prior
approval from Zimmer GmbH.
9. The specied maintenance intervals are to be observed; also refer to the "Maintenance" section.
When the gripper is used under extreme conditions, the maintenance interval must be adapted de-
pending on the extent of the soiling. Please contact our hotline for this purpose.
10.Use of the gripper under extreme conditions, such as aggressive liquids and abrasive dusts, is sub-
ject to prior approval from Zimmer GmbH.
11.When disassembling grippers with integrated springs, exercise heightened caution because spring
tension is always present.
12.Do not reach into the operational range of the gripper!

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DDOC00211 / h EN / 2020-08-15
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
3. Proper use
NOTICE:
The gripper is to be used only in its original state with its original accessories, without any unauthorized
changes and within the scope of its dened parameters of use.
Zimmer GmbH shall accept no liability for any damage caused by improper use.
Use outside of the dened parameters is not permitted. Unauthorized electrical or mechanical modications must not
be made.
The gripper is designed exclusively for electric operation using a supply voltage of 24 VDC.
The gripper is designated for use in enclosed rooms for temporarily gripping, handling and holding parts.
The gripper 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 specialists. These personnel must have read
and understood the installation and operating instructions in full.

INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
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DDOC00211 / hEN / 2020-08-15
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
5. Product description
NOTICE:
To ensure that the gripper jaws do not get deformed, care must be taken to ensure 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.
CAUTION:
Reduction of gripping force
Reduce the gripping force of the gripper when gripping exible components.
A reduced gripping force can lead to material damage or injury to personnel, because the components
that are being gripped can no longer be securely gripped and transported.
5.1 Possible applications
Inside gripping:
The gripper can be used for inside grip-
ping.
Outside gripping:
The gripper can be used for outside
gripping.
5.2 Forces and torques
INFORMATION:
For information on forces and torques, please visit our website.
Zimmer Customer Service is available to provide you with assistance if you have any further questions.
5.3 Type plate
A type plate is attached to the housing of the gripper.
The serial number and the article number are shown on this type plate.
►The serial number should be assigned to the project.
ÖArticle number: dl
ÖSerial number: dm
INFORMATION:
Please state the serial number in the event of damage or a complaint.
Zimmer Customer Service is available to provide you with assistance if you have any further questions.
InnengreifenAußengreifen

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DDOC00211 / h EN / 2020-08-15
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
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.
Fig. 1: Cutaway view of the GEP5000 series gripper
Fig. 2: Cutaway view of the GED5000 series gripper
6.1 Electrical specications
INFORMATION:
For information on electrical specications, please visit our website.
This data varies within the series, depending on the specic design.
Zimmer Customer Service is available to provide you with assistance if you have any further questions.
1Double-lip seal
2Guide rail
3Integrated control module
4Power supply
5Removable centering sleeve
6Gripper jaws
7Positively driven wedge hook transmis-
sion
8Mounting and positioning
9BLDC motor

INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
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DDOC00211 / hEN / 2020-08-15
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
6.2 LED display
6.2.1 LED display for GEP/GED5000IO statuses
INFORMATION:
The control panels cp, cq and cr for the gripper congurations can only be used with the IO variants.
Zimmer Customer Service is available to provide you with assistance if you have any further questions.
6.2.2 LED display for GEP/GED5000IO gripper positions
cl Power/communication
cm Error
cn Position display/menu
co Parameter display
Binary error code display
cp Plus button
Increase parameter value
cq Set button
cr Minus button
Decrease parameter value
cp
cl
cm
co
cq
cr
cn
cn
Gripper is at base position
("BasePosition")
Open gripper jaws
Gripper is at workpiece posi-
tion ("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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DDOC00211 / h EN / 2020-08-15
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
6.2.3 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-
gurations of the functions and settings are made via the control system.
Zimmer Customer Service is available to provide you with assistance if you have any further questions.
6.3 Veried conguration
INFORMATION:
For information about the veried conguration, please visit our website.
Zimmer Customer Service is available to provide you with assistance if you have any further questions.
6.4 Protection classes
NOTICE:
The gripper achieves protection class IP40 in all mounted positions of installation.
6.5 Technical data
INFORMATION:
For information on technical data, please visit our website.
This data varies within the series, depending on the specic design.
Zimmer Customer Service is available to provide you with assistance if you have any further questions.
6.6 Self locking mechanism
INFORMATION:
The gripper has a mechanical self locking mechanism to ensure that the workpiece remains held by the
gripper in the event of power supply loss or failure (such as an emergency stop).
Zimmer Customer Service is available to provide you with assistance if you have any further questions.
6.7 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
Model 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.

INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
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DDOC00211 / hEN / 2020-08-15
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
6.7.1 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
Model 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
6.7.2 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
Model 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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DDOC00211 / h EN / 2020-08-15
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
7. Installation
7.1 Safety notes
NOTICE:
Switch o the energy supply for the electronics before any assembly, installation or maintenance work.
►Electronics may get damaged.
CAUTION:
Switch o the energy supply for the electronics before any assembly, installation or maintenance work.
►Injuries are possible.
WARNING:
Risk of injury in case of unexpected movement of the machine or system into which the gripper is to be
installed.
► Switch o the power supply to the machine before all work.
►Secure the machine against being switched on unintentionally.
►Check the machine for any residual energy.
7.2 Installing the mechanical system
7.2.1 Installing the GEP5000
The gripper must be installed on a mounting surface
in accordance with the atness specications.
Length < 100 mm  permitted atness imperfection
< 0.02 mm
Length > 100 mm  permitted atness imperfection
< 0.05 mm
ÖThe mounting screws are not included in the
scope of delivery.
ÖStrength class of the mounting screws ≥ 8.8 (DIN
EN ISO 4762).
ÖObserve the tightening torque of the mounting
screws.
ÖMake sure the mounting surface is suciently
rigid and at.
ÖUse an adapter plate as needed. For information
on adapter plates, please refer to the accessories
list, available on our website.
The gripper can be installed with its base or laterally
onto the mounting piece.
The following work steps must be observed during
installation:
►Insert the centering sleeves bm into the designat-
ed 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 grip-
per to the mounting piece.
bm
bl
bm
bm

INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
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DDOC00211 / hEN / 2020-08-15
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
7.2.2 Installing the GED5000
The gripper must be installed on a mounting surface in
accordance with the atness specications.
Diameter < 100 mm  permitted atness imperfection <
0.02 mm
Diameter < 100 mm  permitted atness imperfection <
0.05 mm
ÖThe mounting screws are not included in the scope of
delivery.
ÖStrength class of the mounting screws ≥ 8.8
(DIN EN ISO 4762).
ÖObserve the tightening torque of the mounting screws.
ÖMake sure the mounting surface is suciently rigid and
at.
ÖUse an adapter plate as needed. For information on
adapter plates, please refer to the accessories list, avail-
able on our website.
The gripper can be mounted with its base on the mounting
piece.
The following work steps must be observed during installa-
tion:
►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.
NOTICE:
Non-compliance may result in material damage.
7.3 Installing the electrical system
7.3.1 Installing the wiring
►Connect the supply cable to the gripper and the control system.
ÖYou can nd the corresponding supply cable on our website
Öwww.zimmer-group.com
bl
bm
bl

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DDOC00211 / h EN / 2020-08-15
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
INFORMATION:
The cables that are used by Zimmer GmbH feature a minimum bending radius of 10 x the outer diame-
ter.
This bending radius must not be undershot!
ÖAll IO-Link cables that are installed in the grippers have an outer diameter of 5 mm and thus have a
bending radius of 50 mm.
ÖFreely suspended cables must be secured to prevent excessive motion loads or pinching.
7.3.2 Installing the GEP/GED5000IL “IO-Link”
PIN assignment of the power supply line:
PIN Color Function Explanation
1Brown Sensor + 24 V DC Power supply for IO-Link communication
2White Actuator + 24 V
DC Actuator supply voltage
3Blue GND sensor Sensor 0 V DC supply voltage
4Black C/Q IO-Link communication
5Gray GND actuator Actuator 0 V DC supply voltage
The following steps must be carried out for commissioning or installing the gripper with IO-Link:
►Connect the gripper to the IO-Link master.
►Secure the voltage supply.
For Port Class A, additional power supply via Y-cable.
7.3.3 Installing the GEP/GED5000IO “Digital”
PIN assignment of the power supply line:
PIN Color Function Explanation
1White DIR Input, control input, open/close gripper,
24 V DC
2Brown WorkPosition Output, “gripper in work position” mes-
sage
3Green Error Output, “error” message
4Yellow TeachPosition Output, “Gripper in programming posi-
tion” message
5Gray BasePosition Output, “Gripper in base position” mes-
sage
6Pink + 24 V DC Supply voltage 24 V DC/5 A
7Blue Teach/Adjust Input, control input, program/adjust
workpiece
8Red GND 0 V DC supply voltage
4
21
6
8
7
5
3

INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
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Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
dl Gripper
dm Internal sensors, gripper position sensing
dn External control and programming unit
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.
1
2
3
4
5
6
7
8GND
24 V DC
dl dm dn

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DDOC00211 / h EN / 2020-08-15
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
7.4 Static charging
The movement of the gripper jaws create low voltages as a result of static charging. These charges cannot be
dissipated if the gripper is installed on an insulating surface and discharge is also not possible through the work-
piece.
NOTICE:
Non-compliance may result in property damage
Grounding the gripper attachment / gripper jaws is recommended if ESD-sensitive parts come into con-
tact with the gripper.
7.5 Heat dissipation
In the event of high ambient temperatures, the gripper has to 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.
7.6 Installing accessories
NOTICE:
Before installing an accessory, make sure it is suitable for use with the selected variant.
For information on all available accessories, please visit our website.
Zimmer Customer Service is available to provide you with assistance if you have any further questions.

INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
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8. Commissioning
8.1 Commissioning the GEP/GED5000IO “Digital”
8.1.1 “Digital” switching sequence
A movement in the desired direction occurs when the corresponding signal is at a high level. After a high level is
detected, the gripper movement occurs until the gripping process ends.
It is important to ensure that, after a gripper movement has taken place, the corresponding signal is reset again
before a signal in the opposite direction is given.
Between withdrawing the signal and the next command, a pause of 10 ms must be observed.
INFORMATION:
ÖThe movement prole only applies to the digital gripper of the GEP/GED5000 series.
0 V
24 V
Imax ≤5 A
Eingang 1 DIR
Stromaufnahme
Greiferpostion
►◄
◄►

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Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
8.1.2 Teaching-in the "TeachPosition"
The following work steps must be followed for teaching-in the gripper:
►Bring the gripper jaws into the desired position.
ÖFor instance, by inserting a workpiece to be gripped.
►Close the gripper by applying a signal at the PIN 1 input.
ÖLED, error display lights up red 
INFORMATION:
Important for handling the gripper!
The error display lights up because the gripper is not able to
reach its end position as a result of the inserted workpiece.
ÖThe gripper is not yet aware that there is a workpiece
located between the gripper ngers.
► Apply a signal at the control input (PIN 7 “Program/adjust workpiece”
or “Teach/Adjust”) for 0.5 to 3.0 seconds.
ÖLED position display lights up green 
INFORMATION:
Important for handling the gripper!
The position of the workpiece has been taught in to the gripper.
The error display () disappears during the next gripping movement of the gripper ngers.
8.1.3 Teaching-in the end positions
The end positions are conrmed by means of outputs PIN 2 (“WorkPosition”) and PIN 5 (“BasePosition”).
The conrmations of the end positions are also visualized via the LED display.
ÖThe end position sensing of the gripper is preset at the factory.
INFORMATION:
If necessary, end positions set at the factory can be re-set via an automatic traversing routine.
The following work steps must be followed for teaching-in the new end positions:
► A signal must be applied to the control input (PIN 7 “Program/adjust workpiece” or “Teach/
Adjust”) for at least 15 seconds.
ÖThe prerequisite is that the DIR signal is simultaneously set to "0".
►After approximately 3 seconds, the traversing routine begins and is automatically completed
after 5 gripping cycles.
Important information:
NOTICE:
Non-compliance may result in property damage
If the DIR signal (control input, open/close gripper) is interrupted before the end of the traversing routine,
the procedure must be repeated because the end positions have not been correctly determined.
INFORMATION:.
Important for handling the gripper!
The factory settings of the end positions are changed.
To restore the factory settings, the end positions must be taught in without gripper ngers and without a
workpiece!

INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
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DDOC00211 / hEN / 2020-08-15
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
8.2 Commissioning the GEP/GED5000IL “IO-Link”
8.2.1 Process data
The option exists for the gripper to be controlled only by the process data transmitted in each cycle.
Outputs: Process data from the IO-Link master to the gripper!
Name Data type
ControlWord UINT 16
DeviceMode UINT 8
Workpiece No. UINT 8
TeachPosition UINT 16
GripForce UINT 8
PositionTolerance UINT 8
Name Data type
StatusWord UINT 16
Diagnosis UINT 16
ActualPosition UINT 16
Gripper
Input
Control system
Edition

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Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Gripper, electric, GEP5000/GED5000 series
8.2.2 IODD import
► Importing the IODD (device description) into the control system.
ÖCall up our website at Öwww.zimmer-group.com
ÖSelect the desired gripper and download the corresponding .zip le via the "Download IODD" link.
ÖThe “.zip le” is required for importing into the control system.
When the hardware conguration is complete and the IO-Link connection to the gripper is established, some
data must be visible in the process input data.
ÖSome control systems demand a byte swap to bring this process data into a logical sequence.
► To determine whether a byte swap is necessary, you can view bit 6 (GripperPLCActive) in the "StatusWord".
► For this purpose, it is necessary to determine whether bit 6 is active in the rst or second status byte.
ÖIf bit 6 is active in the rst byte, the bytes already have the correct sequence and commissioning can
be continued.
ÖIf bit 6 is active in the second byte, a byte swap still has to be applied here.
ÖFor further information, refer to the "StatusWord" section.
INFORMATION:
It is mandatory to verify the process data.
The control of the gripper takes place via IO-Link by means of the cyclical process data as well as the acyclical
service data with a cycle time of 5 ms.
8.3 "Handshake" data transfer method
All process data that is transferred to the gripper and is described in the sections that follow must be transferred
using the "handshake" method.
INFORMATION:
This method is referred to as a "handshake" because it enables "clean" transfer.
The process data transfer takes place, so to speak, from "hand to hand" - from the control system to the
gripper.
The following steps are required for the "handshake":
The data transfer starts with the transfer of "ControlWord" = 0x01 to the gripper.
Subsequently, the response of the gripper must be tested by means of "Statusbit" 12 = TRUE  (data trans-
fer OK).
Following this, the “ControlWord” = 0 can be sent, which ends the data transfer.
The operator automatically concludes the data transfer with the “ControlWord” = 0x00 and the corre-
sponding response from the gripper via the “Statusbit” 12 = FALSE .