Zimmer WWR Series User manual

INSTALLATION AND
OPERATING
INSTRUCTIONS
Pneumatic tool changer
WWR series
DDOC00227
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
4.1 Electricians ...........................................................................................................................................................................................................................6
4.2 Specialists ............................................................................................................................................................................................................................6
4.3 Instructed personnel............................................................................................................................................................................................................6
4.4 Service personnel................................................................................................................................................................................................................6
4.5 Additional qualications......................................................................................................................................................................................................6
5 Product description ..................................................................................................................................................................... 7
5.1 Type plate .............................................................................................................................................................................................................................8
5.2 Product variants and compatibility.....................................................................................................................................................................................8
6 Functional description ................................................................................................................................................................. 9
6.1 Functional safety ................................................................................................................................................................................................................10
6.2 Control ................................................................................................................................................................................................................................10
6.3 Self-locking mechanism ....................................................................................................................................................................................................10
7 Technical data ............................................................................................................................................................................10
7.1 Protection class..................................................................................................................................................................................................................10
8 Accessories ................................................................................................................................................................................11
9 Transportation/storage/preservation....................................................................................................................................... 11
10 Installation .................................................................................................................................................................................. 12
10.1 Installing the stationary part..............................................................................................................................................................................................13
10.2 Installing the loose part .....................................................................................................................................................................................................13
10.3 Installing the energy supply ..............................................................................................................................................................................................14
10.3.1 Pneumatic control categories.............................................................................................................................................................................15
10.4 Mounting the magnetic eld sensor.................................................................................................................................................................................17
10.4.1 WWR40F, WWR50F, WWR63F installation sizes ..............................................................................................................................................17
10.4.2 WWR80F installation size....................................................................................................................................................................................19
10.4.3 WWR100F installation size..................................................................................................................................................................................20
10.4.4 WWR125F installation size..................................................................................................................................................................................21
10.4.5 WWR160F installation size..................................................................................................................................................................................22
10.5 Installing the inductive sensor ..........................................................................................................................................................................................23
10.6 Installing the storage station.............................................................................................................................................................................................24
10.7 Installing accessories ........................................................................................................................................................................................................24
11 Maintenance............................................................................................................................................................................... 25
12 Decommissioning/disposal ...................................................................................................................................................... 25
13 RoHS declaration....................................................................................................................................................................... 26
14 Declaration of Incorporation ..................................................................................................................................................... 27
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com
Content

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.
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15

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 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 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.
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15
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.
• The product is designed exclusively for pneumatic operation.
►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 intended for industrial use.
• The product is designated for use in closed facilities.
• Direct contact with perishable goods/food is not permitted.
• Observance of the technical data and of the installation and operating instructions are part of proper use.
4 Personnel qualication
WARNING
Injuries and material damage due to inadequate qualication
If inadequately qualied personnel perform work on the product, this can cause serious injuries and signicant
material damage.
►All work on the product must be performed by qualied personnel.
►Before working with the product, read the document in its entirety and make sure that you have understood
everything.
►Observe country-specic accident prevention regulations and the general safety notices.
The following qualications are a prerequisite for performing various work on the product.
4.1 Electricians
Electricians are able to perform work on electrical systems, can recognize and avoid possible dangers and know the
relevant standards and provisions due to their technical training, knowledge and experience.
4.2 Specialists
Specialists are able to perform the assigned work, can recognize and avoid possible dangers and know the relevant
standards and provisions due to their technical training, knowledge and experience.
4.3 Instructed personnel
Instructed personnel have been trained by the operating company on the tasks and possible dangers of improper behavior.
4.4 Service personnel
Service personnel are able to perform the assigned work and can recognize and avoid possible dangers due to their
technical training, knowledge and experience.
4.5 Additional qualications
Persons who work with the product must be familiar with the valid safety regulations and laws as well as the standards,
guidelines and laws listed in this document.
Personnel who work with the product must have facility-issued authorization to commission, program, congure, operate,
maintain and also decommission this product.
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15

7
5 Product description
The product is a pneumatically operated exchange system.
It consists of a loose part and a stationary part. A storage station is available as an option.
The basic and proven safety principles from ENISO13849-1 can be complied with only if original parts from Zimmer GmbH
are used.
The original parts from Zimmer GmbH required for the safety principles are:
1
2
1Stationary part (WWRxxF-B)
2Loose part (WWRxxL-B)
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

8
5.1 Type plate
A type plate is attached to the housing of the product.
XXX
XX-XXXXXX
am
an
The article number and the conrmation number are shown on the type
plate.
am Article number
an Conrmation number
5.2 Product variants and compatibility
INFORMATION
Depending on the installation size of the product, several transmission elements are available for the actuator
power supply.
Optionally, the media transmission can be set up with transmission elements at corresponding interfaces on the
tool changer.
►Please contact Zimmer Customer Service if you have any questions.
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15

9
6 Functional description
INFORMATION
• The product is designed exclusively for pneumatic operation.
►Always operate the product with an operating pressure between 4 and 10bar.
The stationary part is installed on a robot system. It is used to hold a loose part.
Several storage stations can be used to hold differently equipped loose parts for operation with a stationary part.
The locking bolts in the locking sleeve enable a friction-locked connection of the stationary and loose part.
The stroke is generated by a double-acting pneumatic rotor cylinder. An integrated spring acts as an energy store and
preserves the capability of product locking in the event of a power failure.
The stationary part can be operated with as many loose parts as desired.
3Pneumatic connection
4Locking bolt
5Integrated pneumatic feed-through
6Locking sleeve
3
4
5
6
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

10
6.1 Functional safety
For the overall safety of the function, both components (stationary part and loose part) must be taken into account.
The safety function that ensures secure locking between the stationary and loose part of the product is implemented via
two redundant action channels. They consist of a pneumatic locking and a mechanical safeguard via a spring.
6.2 Control
INFORMATION
►You can nd the information in the technical data sheet on our website.
►Please contact Zimmer Customer Service if you have any questions.
6.3 Self-locking mechanism
INFORMATION
The safety of product locking in the event of a loss of pressure or voltage is ensured by an integrated spring.
►Please contact Zimmer Customer Service if you have any questions.
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.
7.1 Protection class
NOTICE
The product achieves protection class IP54 in all mounted positions of installation.
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15

11
8 Accessories
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.
►Avoid wind/drafts/water condensation formation.
►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: WWR
DDOC00227 / p EN / 2023-05-15
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

12
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 being switched on unintentionally.
►Check the machine for any residual energy that may be present.
NOTICE
►Please note that when using hose-free connections, the O-rings must be inserted into the customer-made
pockets of the holes on the mounting surface.
►Note the specied screw lengths.
INFORMATION
Further installation information:
• Mounting screws are included in the scope of delivery.
Assembly requirements
Permissible unevenness [mm] Mounting surface length [mm] < 100 < 0.02
Mounting surface length [mm] > 100 < 0.05
Strength class of the mounting screws (ENISO4762) 8.8
►You can nd the exact installation positions in the technical data sheet on our website.
►Install the product on an appropriate mounting surface in accordance with the atness specications.
►Make sure that the mounting surface of the product and connection structure are clean.
►Observe the tightening torque of the mounting screws.
►Verify the permitted load capacity of the required screw connections in accordance with VDI 2230.
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15

13
10.1 Installing the stationary part
INFORMATION
►Note the screw-in depth.
• Screw-in depth ≥ 1.5 x diameter.
►Insert the straight pin into the designated t on the stationary part. 7
8
9
►Insert the stationary part into the robot arm by the connection.
►Position the stationary part on the robot.
►Loosely attach the mounting screws.
►Tighten the mounting screws crosswise.
7Straight pins
8Connection
9Mounting screw
10.2 Installing the loose part
►Insert the straight pin into the designated t on the loose part.
7
9
►Position the loose part on the tool.
7Straight pins
9Mounting screw
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

14
10.3 Installing the energy supply
►Mount the push-t tting.
bl
►Use the marked connections A and B for
this purpose.
bl Push-t tting
NOTICE
►You can nd information on available pneumatic connections on our website.
►Close off unused connections using pressure-resistant closures.
►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].
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15

15
10.3.1 Pneumatic control categories
INFORMATION
►Please note that the connection to the Amarking is used for product locking.
►Please note that the connection to the Bmarking is used for product unlocking.
The following examples show two control categories. In accordance with ENISO13849-1, the product can be controlled so
that the required performance level is achieved.
INFORMATION
The product can be actuated and operated using any control architecture in accordance with ENISO13849-1.
The deciding factor here is which performance level PLrshould be achieved.
►Please note the MTTFdvalues of the safety-related parts of the control system (SRP/CS) being used as well as
the degree of diagnostic coverage (DC) achieved.
INFORMATION
The secure holding of coupled tools must be taken into account as this is a relevant safety function for the
product.
Risk prevention can be achieved through the use of various protection measures, both via SRP/CS measures as
well as via non-SRP/CS measures. The goal of the protection measures is to reach a safe status.
Measures for fault prevention su󹱺ce for applications with a risk of PLra to PLrc.
For applications with a risk higher than PLrd to PLre, the structure of the SRP/CS can provide the measures to
avoid, note or tolerate the faults.
Suitable measures include redundancy, diversity and monitoring in accordance with ENISO12100-2:2003,
Section3 and ENIEC60204-1:2000.
10.3.1.1 Control category 1 example
Single-channel
The mechanical component (spring) is
supported by the pneumatic component
(pressure).
Both components alone cannot maintain the
safety function.
• Proven components
• 0 Fault detection
• Activation via a 5/2-way valve
ÖPLcis achieved.
In order to achieve the safety function, the use
of proven components in accordance with
ENISO13849-1, Chapter6.2.4 are su󹱺cient.
• Magnetic eld sensors S3 and S4 are
available for the nal position check.
1
2
3
4
5
WWR
V2
A
B
S3
S4
S3 S4
GG
WWR
AB
Control signal
"locked"
Control signal
"unlocked"
Unlocked
Locked
Unlocked
Locked
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

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10.3.1.2 Control category 3 example
Dual-channel
• The mechanical component (spring)
operates as action channel 1 (yellow
marking).
• The pneumatic component (pressure)
operates as action channel 2 (blue marking).
ÖEach of the individual components alone
can maintain the safety function.
There is fault elimination in accordance with
ENISO13849-2, AnnexA, TableA.5 for the
mechanical action channel.
There is a B10d value of 5million cycles for the
pneumatic action channel.
WWR
S3
S4
A
B
G G
S3 S4
S1S2
GG
WWR
AB
R1
V1
V2
Control signal
"unlocked"
Unlocked
Locked
Unlocked
Locked
Control signal
"locked"
• The degree of diagnostic coverage is
60%≤DC<90%.
• Two mono-stable valves are used.
ÖThe safety functions "reversing" and/
or "unexpected startup" (unlock) are
realized.
ÖPLdto 100% can be achieved.
• Optional magnetic eld sensors (S3 and
S4) or a 2-point magnetic eld sensor are
available for the nal position check.
• An optional pressure sensor can be used for
pressure monitoring.
ÖThis can increase the degree of
diagnostic coverage to 90%≤DC<99%.
• Optional sensors are available for storage
station monitoring.
• Optional energy elements are available for
tool coding.
• Optional sensors are available for "loose
part present" sensing.
NOTICE
►Please note that the maximum handling weight, the associated lever arms and the acceleration values may not
be exceeded for the implementation of control category 3.
►Refer to the technical data sheet on our website for the values for the maximum handling weight.
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15

17
10.4 Mounting the magnetic eld sensor
Various sensors are available for sensing the piston position depending on the installation size. These sensors provide
information on the respective position of the piston and increase safety when operating the product.
bm Opening on the stationary part
bn Sealing
bm
bn
10.4.1 WWR40F, WWR50F, WWR63F installation sizes
Design size 1-point magnetic eld sensor
WWR40F ZUB0015
WWR50F ZUB0016
WWR63F ZUB0017
Design size 2-point magnetic eld sensor
WWR40F ZUB088929
WWR50F ZUB088928
WWR63F ZUB088927
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

18
As an example, the gures show the installation
of sensors ZUB0015 and ZUB088929.
ZUB0015
bq
bpbo
ZUB088929
bq
bp
bo
►Remove the seal.
►Slide the sensors into the sensor bracket.
►Securely clamp the sensors with the grub
screw.
►Insert the sensor bracket into the opening
on the stationary part.
►Securely clamp the sensor bracket using the
grub screw.
bo Sensor
bp Sensor bracket
bq Grub screw
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15

19
10.4.2 WWR80F installation size
Design size 1-point magnetic eld sensor
WWR80F ZUB0018
Design size 2-point magnetic eld sensor
WWR80F ZUB088925
As an example, the gures show the installation
of a 1-point and 2-point magnetic eld sensor.
ZUB0018
bq
bo
bp
bs bt
br
ZUB088925
bq
bt
bp
bo
br
bu
bs
►Remove the seal.
►Slide the sensors into the sensor bracket.
►Securely clamp the sensors with the grub
screw.
►Position the spacer on the sensor bracket
with the grub screw and the straight pin.
►Install the components with the mounting
screw.
►Insert the sensor bracket into the opening
on the stationary part up to the end stop.
►Secure the sensor bracket into position from
above with the grub screws.
bo Sensor
bp Sensor bracket
bq Grub screw
br Spacer
bs Straight pins
bt Mounting screw
bu Grub screw
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

20
10.4.3 WWR100F installation size
Design size 1-point magnetic eld sensor
WWR100F ZUB0019
Design size 2-point magnetic eld sensor
WWR100F ZUB088924
As an example, the gures show the installation
of a 1-point and 2-point magnetic eld sensor.
ZUB0019
bo
br
cl
ct
bp
bp
ZUB088924
bo
bpbrcl
►Remove the seal.
►Slide the sensors into the sensor bracket.
►Position the spacer on the sensor bracket.
►Slide the sensor bracket into the opening on
the stationary part up to the end stop.
►Make sure that the marking on the
sensor bracket faces downwards.
►Route the sensor cables through the holes
of the cover plate.
►Install the cover plate to the opening on the
stationary part.
bo Sensor
bp Sensor bracket
br Spacer
cl Cover plate
ct Marking
Zimmer GmbH •Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: WWR
DDOC00227 / p EN / 2023-05-15