Zimmer DVR Series User manual

INSTALLATION AND
OPERATING INSTRUC-
TIONS
DVR series
Rotary distributor
DDOC00222
THE KNOW-HOW FACTORY
www.zimmer-group.com

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DDOC00222 / e EN / 2020-01-21
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Rotary distributor, pneumatic/electric, DVR series

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary distributor, pneumatic/electric, DVR series
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DDOC00222 / e
EN / 2020-01-21
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
Contents
1 Supporting documents.......................................................................................................................................................4
1.1 Hazard levels of warning notices ..................................................................................................................................................................... 4
2 Safety notices ......................................................................................................................................................................5
3 Proper use............................................................................................................................................................................5
4 Personnelqualication .......................................................................................................................................................5
5 Product description.............................................................................................................................................................6
5.1 Forces and torques ...........................................................................................................................................................................................6
5.2 Type plate ......................................................................................................................................................................................................... 6
5.3 Protection class.................................................................................................................................................................................................6
5.4 Function .............................................................................................................................................................................................................6
5.5 Product design..................................................................................................................................................................................................7
6 Accessories/scope of delivery ...........................................................................................................................................7
7 Technical data......................................................................................................................................................................7
8 Installation............................................................................................................................................................................8
8.1 General installation information .......................................................................................................................................................................8
8.2 Installing the product ........................................................................................................................................................................................8
8.3 Installing the product on the robot .................................................................................................................................................................. 9
8.4 Installing the product on the tool .....................................................................................................................................................................9
8.5 Installing the electrical system .......................................................................................................................................................................10
8.5.1 Installing the wiring .........................................................................................................................................................................................10
8.5.2 PIN assignment ...............................................................................................................................................................................................10
8.6 Installing the pneumatic system ....................................................................................................................................................................12
8.7 Connecting the sealing air..............................................................................................................................................................................12
8.8 Installing accessories .....................................................................................................................................................................................12
8.9 Installing the torque brace..............................................................................................................................................................................13
9 Disassembly.......................................................................................................................................................................13
9.1 Safety notices ..................................................................................................................................................................................................13
10 Maintenance ......................................................................................................................................................................14
11 Transportation/storage/preservation ..............................................................................................................................14
12 Decommissioning and disposal.......................................................................................................................................14
13 RoHS declaration ..............................................................................................................................................................15
14 REACH declaration ...........................................................................................................................................................15
16 Declaration of Incorporation.............................................................................................................................................16

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DDOC00222 / e EN / 2020-01-21
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Rotary distributor, pneumatic/electric, DVR series
1 Supporting documents
NOTICE
Read through the installation and operating instructions 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 lifetime.
The documents listed below are available for download on our website www.zimmer-group.com:
• Installation and operating instructions
• Declaration of Incorporation
• Catalogs, drawings, CAD data, performance data, exploded drawing
• Information on accessories
• Spare parts list
• Technical data sheets
• General Terms and Conditions, including warranty information
Only those documents currently available on the website are valid.
1.1 Hazard levels of warning notices
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!
• The 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!
• The 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!
• The warning symbols are assigned according to the type of danger.
NOTICE
General notices contain usage tips and valuable information, but no warnings of dangers to health.
INFORMATION
This category contains useful tips for handling the product e󹱺ciently. Failure to observe these tips will not result
in damage to the product. This information does not include any information relevant to health or workplace
safety.

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary distributor, pneumatic/electric, DVR series
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DDOC00222 / e
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Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
2 Safety notices
CAUTION
Risk of injury and material damage in case of non-compliance
Installation, commissioning, maintenance and repairs may only be performed by qualied specialists in
accordance with these installation and operating instructions.
The product is state-of-the-art. It is tted to industrial machines and is used to hold, transport and store
workpieces.
The product can only cause a hazard if:
• 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
Zimmer GmbH shall accept no liability for any damage caused by improper use. The operator bears sole respon-
sibility.
Installation, commissioning, maintenance and repairs may only be performed by qualied specialists in
accordance with these installation and operating instructions.
►Make sure that the power cables are disconnected before you install, retool, maintain or repair the product.
►When using the product under extreme conditions, adjust the maintenance interval according to the degree
of contamination.
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.
Zimmer GmbH shall accept no liability for any damage caused by improper use. The user bears sole responsi-
bility.
The product is designed exclusively for pneumatic and electric operation within the agreed-upon parameter limits and
conditions of use. Unauthorized electrical or mechanical modications must not be made. The product is intended for use
in enclosed spaces for transferring electrical and pneumatic energies through rotating connections. The product prevents
cables and lines from twisting. It is not suited for direct contact with perishable goods.
4 Personnel qualication
Installation, commissioning and maintenance may only be performed by trained specialists. These persons must have read
and understood the installation and operating instructions in full.
5 Product description
5.1 Forces and torques
INFORMATION
For information about forces and torques, refer to our website at www.zimmer-group.com.
Please contact Zimmer Customer Service if you have any questions.

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DDOC00222 / e EN / 2020-01-21
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Rotary distributor, pneumatic/electric, DVR series
5.2 Type plate
A type plate is attached to the housing of the product.
The type plate shows the part number amand serial number an. XXX
XX-XXXXXX
am
an
INFORMATION
Please state the serial number anin the event of damage or a complaint.
Please contact Zimmer Customer Service if you have any questions.
5.3 Protection class
NOTICE
The product achieves protection class IP40 in all mounted positions of installation.
5.4 Function
The rotary distributor is designed as a compact device for media transfer. The housing functions as a stator due to the
torque brace. This is where the media to be transferred are brought in. The robot ange and the tool-side connecting ange
are the rotating elements. The structural design of the robot ange is based on the specications from DIN EN ISO 9409-1.
The rotary distributor prevents cable breaks, damage or cracks in pneumatic lines, as there are no interference contours
resulting from exposed lines. The compact design reduces the torque loads for the handling system to a minimum. In the
interior, the gold contacts of the slip ring provide high exibility in the electrical transmission of low currents up to 250V and
a maximum of 6A.
5.5 Product design
1Up to 8-way integrated
pneumatic feed-through
2Sealing air
3Mounting and positioning
4Robot ange
5Up to 12-pin power supply
6Torque brace
7Direct air connection
8Tool ange
9Housing
2
5
3
4
1
8
6
9
7

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary distributor, pneumatic/electric, DVR series
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Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
6 Accessories/scope of delivery
INFORMATION
Proper operation of the rotary distributor is only guaranteed if accessories sold or authorized by Zimmer GmbH
are used.
For information on optional accessories included in the scope of delivery, refer to our website at www.
zimmer-group.com.
7 Technical data
INFORMATION
For technical data, refer to our website at www.zimmer-group.com.
The technical data vary within the series depending on the specic design.
Please contact Zimmer Customer Service if you have any questions.

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DDOC00222 / e EN / 2020-01-21
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Rotary distributor, pneumatic/electric, DVR series
8 Installation
8.1 General installation information
WARNING
Risk of injury due to uncontrolled movements
Considerable crushing injuries can result from uncontrolled movements.
Risk of injury in case of uncontrolled movements of the machine or system into which the product is to be
installed.
►Switch off the power supply to the product before all work.
►Switch off the power supply of the machine before all work.
►Secure the power supply against being switched on unintentionally.
►Check the machine for any residual energy that may be present.
CAUTION
Switch off the electronic and pneumatic supply before any assembly, installation or maintenance work.
ÖInjuries are possible.
ÖElectronics may get damaged.
NOTICE
Installation may only be carried out by qualied personnel in accordance with these installation and operating
instructions.
►Switch off the power supply before any assembly, installation or maintenance work.
►To prevent the following, make sure that the tool ange and the housing are not separated from each other
during disassembly:
• Malfunctions
• Damage to the unit
If an accidental disconnection should nevertheless occur, the electrical sliding contacts in the interior must not
be touched. Bring the two parts brought back together carefully.
►Install the product according to the specications for atness on a mounting surface with a maximum permissible
unevenness of 0.03.
• The mounting screws are not included in the scope of delivery. Use mounting screws of a strength class ≥ 8.8 (DIN EN
ISO 4762).
• Comply with the tightening torques of the mounting screws.
• Make sure that the mounting surface is su󹱺ciently rigid and at.
8.2 Installing the product
The rotary distributor is installed between the robot ange and the tool. When selecting the model and variant of the
rotary distributor, the design of connecting ange on the robot in accordance with EN ISO 9409-1 and the functions to be
implemented on the tool should be taken into account.
• Installation rst takes place on the robot ange because the central screw still has to be accessible.
• The tool can then be installed.

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary distributor, pneumatic/electric, DVR series
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DDOC00222 / e
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Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
8.3 Installing the product on the robot
►Loosen the cylinder screw bm.
►Lift the robot ange 4with the mounting screws bl.
►Use the mounting screws to secure the robot ange to
the mounting piece.
►Follow the screw-in depth listed in the table provided
in EN ISO 9409-1.
►Bring the housing and the robot ange together again.
►Use the cylinder screw to connect the housing and the
robot ange.
4
bm
bl
8.4 Installing the product on the tool
►Insert the straight pin bn into the provided matching
part on the tool ange.
►Use the straight pin to position the tool changer or tool
on the tool ange.
►Use the mounting screws boto secure the tool changer
or tool to the tool ange.
►Follow the screw-in depth listed in the table provided
in EN ISO 9409-1.
bo
bn

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DDOC00222 / e EN / 2020-01-21
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Rotary distributor, pneumatic/electric, DVR series
8.5 Installing the electrical system
8.5.1 Installing the wiring
►Connect the supply cable to the rotary distributor and the control system.
8.5.2 PIN assignment
PIN assignment of the power supply line for models DVR40I4 and DVR50I4
Connec-
tor
Female
connec-
tor
1 1
2 2
3 3
4 4
1
2
3
4
3
4
1
2
PIN assignment of the power supply line for models DVR63I6 and DVR80I6
Connec-
tor
Female
connec-
tor
1 1
2 2
3 3
4 4
5 5
6 6
7n. c. 7
8n. c. 8
9n.c. 9
54321
9876
1
9
5432
876

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary distributor, pneumatic/electric, DVR series
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DDOC00222 / e
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Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
PIN assignment of the power supply line for models DVR100I4 and DVR100I8
Connec-
tor
Female
connec-
tor
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9n.c. 9
54321
9876
1
9
5432
876
PIN assignment of the power supply line for models DVR125I4, DVR125I8, DVR160I4 and DVR160I8
Connec-
tor
Female
connec-
tor
1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9
10  10
11  11
12  12
13 n.c. 13
14 n.c. 14
15 n.c. 15
54321 6 7 8
9 10 11 12 13 14 15
54 3 2 1 678
9101112131415

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Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Rotary distributor, pneumatic/electric, DVR series
8.6 Installing the pneumatic system
The following inputs and outputs are available on the rotary
distributor:
• Circumference on the housing = inputs bpon the robot
• Circumference on the tool ange = outputs bq on the tool
• The assignments of the inputs and outputs can be
indicated by assigning numbering bs.
Recommendation for a tubeless connection:
To enable a tubeless connection between the tool and
rotary distributor, using a Zimmer GmbH tool changer is
recommended. There are matching pneumatic energy
supplies bravailable on the front side of the tool ange for
this purpose.
bs
brbr
bq
bp
INFORMATION
►Close off unused pneumatic connections using suitable dummy plugs.
Please contact Zimmer Customer Service if you have any questions.
8.7 Connecting the sealing air
INFORMATION
►For the sealing air, use compressed air in accordance with ISO 8573-1 [2:4:1].
Otherwise, there is a risk of damage to the electronic transfer elements.
ÖReduced maintenance intervals
The sealing air can be connected to connection 2.
• p max = 0.5 bar
2
8.8 Installing accessories
NOTICE
Before mounting the accessories, check whether they are suitable for use with the selected series.
INFORMATION
For information about the complete range of accessories, refer to our website at www.zimmer-group.com.
Please contact Zimmer Customer Service if you have any questions.

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary distributor, pneumatic/electric, DVR series
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Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
8.9 Installing the torque brace
NOTICE
The torque brace is designed so that no lateral torques are introduced into the “oating” central part of the rotary
distributor. For this reason, the torque brace must be implemented as depicted.
Exchanging the standard torque brace for a xed 2-point threaded connection on the central part may damage
the seals and the internal electric slip ring system.
• The required specication bufor the bolt diameter cl is
mapped on the torque brace 6.
• The bolt must be manufactured according to the
following standard:
• DIN ISO 2768-1
• Table 1 (general tolerances for length dimensions)
• Aim for production at the lower tolerance limit.
• The bolt of the torque brace must be positioned parallel
to the rotational axis or casing surface of the rotary
distributor.
ÖParallelism tolerance = 0.1mm
bu
cl
6
9 Disassembly
9.1 Safety notices
WARNING
Risk of injury due to uncontrolled movements
Considerable crushing injuries can result from uncontrolled movements.
Risk of injury in case of uncontrolled movements of the machine or system into which the product is to be
installed.
►Switch off the power supply to the product before all work.
►Switch off the power supply of the machine before all work.
►Secure the power supply against being switched on unintentionally.
►Check the machine for any residual energy that may be present.
CAUTION
Switch off the electronic and pneumatic supply before any assembly, installation or maintenance work.
►Injuries are possible.
►Electronics may get damaged.
NOTICE
Disassembly may only be carried out by qualied personnel in accordance with these installation and operating
instructions.
►Switch off the power supply before any assembly, installation or maintenance work.
►To prevent the following, make sure that the tool ange and the housing are not separated from each other
during disassembly:
• Malfunctions
• Damage to the unit
If an accidental disconnection should nevertheless occur, the electrical sliding contacts in the interior must not
be touched. The two parts should be brought back together carefully!

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DDOC00222 / e EN / 2020-01-21
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Rotary distributor, pneumatic/electric, DVR series
10 Maintenance
CAUTION
Risk of injury due to improper maintenance
►During maintenance of the product, observe the locally valid workplace safety regulations.
►Only appoint trained personnel.
►Switch off the power supply.
Maintenance-free operation of the product is guaranteed for up to 10million rotations.
In the event of continuous operation with sealing air, the rotary distributor must be uninstalled and relubricated at least
every six months. This maintenance work may only be carried out by Zimmer Customer Service.
If the rotary distributor is exposed to a constantly alternating direction of rotation, the maximum number of revolutions will
not be reached.
The actual service life depends on the following factors:
• Revolutions
• Speed
• Changes in direction of rotation
• Ambient conditions
• Handling weight
• Electrical voltage and amperage
• Continuous operation with sealing air and its quality
Even though the product is maintenance-free as mentioned above, perform a regular visual inspection to check for any
corrosion, damage or contamination.
We recommend allowing maintenance and seal replacement to be carried out by Zimmer Customer Service.
Unauthorized dismantling and reassembling may result in complications as special installation equipment is required in
some cases. Zimmer GmbH accepts no liability for any resulting malfunctions or damage.
11 Transportation/storage/preservation
►Transport and store the product only in the original packaging.
►During transport, make sure that no uncontrolled movements can occur if the product is already mounted on the
higher-level machine unit.
►Prior to commissioning after transport, check all power and communication connections as well as all mechanical
connections.
►If the product is stored for an extended period, observe the following points:
►Keep the storage area dust-free and dry.
►Observe the temperature range and avoid temperature uctuations.
►Avoid wind, drafts and formation of condensation.
►Cover the product with a weatherproof, tear-resistant foil to prevent dust.
►Avoid direct sunlight.
►Clean all components. There must be no dirt left on the components.
►Visually inspect all components.
►Remove and foreign objects.
►Remove potential corrosion spots properly.
►Seal electrical connections by using suitable covers.
12 Decommissioning and disposal
INFORMATION
When the product reaches the end of its service life, it can be completely disassembled and disposed of.
►Disconnect the product completely from the power supply.
►Dispose of the components properly according to the material groups.
►Comply with the locally applicable environmental and disposal regulations.

INSTALLATION AND OPERATING INSTRUCTIONS: Rotary distributor, pneumatic/electric, DVR series
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Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
13 RoHS declaration
In terms of the EU Directive 2011/65/EU
Name and address of the manufacturer:
Zimmer GmbH
Im Salmenkopf 5, 77866 Rheinau, Germany
[phone]
[phone]
www.zimmer-group.com
We hereby declare that the incomplete machine described below
Product designation: Rotary distributor, pneumatic, electric
Type designation: DVR
conforms to the requirements of the directive in its design and the version we put on the market.
Michael Hoch Rheinau, Germany, 2021-03-25
Authorized representative for
compiling the relevant technical
documents
(Place and date of issuance) Martin Zimmer
(Legally binding signature)
Managing Partner
14 REACH declaration
In terms of the EU Regulation 1907/2006
Name and address of the manufacturer:
Zimmer GmbH
Im Salmenkopf 5, 77866 Rheinau, Germany
[phone]
[phone]
www.zimmer-group.com
REACH stands for Registration, Evaluation, Authorisation and Restriction of Chemicals.
A full declaration of REACH can be obtained from the manufacturer due to the duty to notify in accordance with Art. 33 of
the REACH regulation ("Duty to communicate information on substances in articles").
Michael Hoch Rheinau, Germany, 2021-03-25
Authorized representative for
compiling the relevant technical
documents
(Place and date of issuance) Martin Zimmer
(Legally binding signature)
Managing Partner

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Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Rotary distributor, pneumatic/electric, DVR series
15 Declaration of Incorporation
In terms of the EU Machinery Directive 2006/42/EC (Annex II 1 B)
Name and address of the manufacturer:
Zimmer GmbH
Im Salmenkopf 5, 77866 Rheinau, Germany
[phone]
[phone]
www.zimmer-group.com
We hereby declare that the incomplete machine described below
Product designation: Rotary distributor, pneumatic, electric
Type designation: DVR
conforms to the requirements of the Machinery Directive, 2006/42/EC, Article 2g, Annex VII, b – Annex II, b, in their design
and the version we put on the market.
The following harmonized standards have been used:
Basic health and safety requirements:
No. 1.1.2., No. 1.1.3., No. 1.1.5., No. 1.3.2., No. 1.3.4., No. 1.3.7., No. 1.5.3., No. 1.5.4., No. 1.5.8., No. 1.6.4., No. 1.7.1., No.
1.7.4
A full list of applied standards can be obtained from the manufacturer.
We also declare that the specic technical documents were produced in accordance with Annex VII Part B of this Directive.
We undertake to provide the market supervisory bodies with electronic versions of special documents for the incomplete
machine through our documentation department, should they have reason to request them.
Commissioning of the incomplete machine is prohibited until it has been found that—where applicable—the machine
in which the above-mentioned incomplete machine is to be installed complies with the Machinery Directive (2006/42/
EC) and an EC Declaration of Conformity has been drawn up in accordance with Annex II 1 A.
Kurt Ross Rheinau, Germany, 2021-03-25
Authorized representative for
compiling the relevant technical
documents
(Place and date of issuance) Martin Zimmer
(Legally binding signature)
Managing Partner