Zimmer CSR Series User manual

www.zimmer-group.de
INSTALLATION AND
OPERATING
INSTRUCTIONS
CSR series
Collision protection
DDOC00267
THE KNOW-HOW FACTORY

INSTALLATION AND OPERATING INSTRUCTIONS: Collision protection, pneumatic, CSR series
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau,Germany •[phone] • [phone] •www.zimmer-group.com
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EN / 2020-09-15DDOC00267 / b

INSTALLATION AND OPERATING INSTRUCTIONS: Collision protection, pneumatic, CSR series
3
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
EN / 2020-09-15DDOC00267 / b
Contents
1 Supporting documents......................................................................................................................................................... 4
2 Safety notes ........................................................................................................................................................................... 4
3 Proper use ............................................................................................................................................................................. 5
4 Personnelqualication ......................................................................................................................................................... 5
5 Product description .............................................................................................................................................................. 5
5.1 Forces and torques .....................................................................................................................................................................................................5
5.2 Type plate.....................................................................................................................................................................................................................5
6 Function ................................................................................................................................................................................. 6
7 Technical data ....................................................................................................................................................................... 6
8 Installation.............................................................................................................................................................................. 7
8.1 General installation information .................................................................................................................................................................................7
8.2 Installing the product on the robot.............................................................................................................................................................................8
8.3 Installing the custom application ...............................................................................................................................................................................8
8.4 Installing the power supply and sensor.....................................................................................................................................................................9
8.5 Installing accessories..................................................................................................................................................................................................9
9 Maintenance........................................................................................................................................................................ 10
10 Accessories / scope of delivery......................................................................................................................................... 10
11 Transportation / storage / preservation ............................................................................................................................ 10
12 Decommissioning and disposal......................................................................................................................................... 10
13 Declaration of Incorporation .............................................................................................................................................. 11

INSTALLATION AND OPERATING INSTRUCTIONS: Collision protection, pneumatic, CSR series
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau,Germany •[phone] • [phone] •www.zimmer-group.com
4
EN / 2020-09-15DDOC00267 / b
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
• Catalogs, drawings, CAD data, performance data
• Information on accessories
• Technical data sheets
• General Terms and Conditions of Business, including warranty information
ÖOnly those documents currently available on the website are valid.
2 Safety notes
CAUTION
Risk of injury in the event of improper installation, commissioning or maintenance and improper use.
Non-compliance may result in severe injuries!
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 installed on industrial machines and used to hold tools or mounting pieces.
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 Accident Prevention Regulations and installation and operating instructions are not observed.
The product may only be used in accordance with these 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.
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 the product is used under extreme conditions, the maintenance interval must be adapted depending
on the extent of the contamination.

INSTALLATION AND OPERATING INSTRUCTIONS: Collision protection, pneumatic, CSR series
5
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
EN / 2020-09-15DDOC00267 / b
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 more extensive use is improper.
►Operate the product only in compliance with the associated installation and operating instructions.
►Operate the product only when it is in a technical condition that corresponds to the guaranteed parameters
and operating conditions.
ÖZimmer GmbH shall accept no liability for any damage caused by improper use. The user bears sole respon-
sibility.
Useoutsideofthedenedparametersisnotpermitted.Unauthorizedelectricalormechanicalmodicationsmustnotbe
made.
The product is not suitable for use as an active compensation module.
Direct contact with perishable goods/food is not permitted.
4 Personnel qualication
Installation,commissioningandmaintenancemayonlybeperformedbyqualiedpersonnel.Thesepersonnelmusthave
read and understood the installation and operating instructions in full.
5 Product description
5.1 Forces and torques
INFORMATION
For information on the forces and torques for the following product, please refer to our website at www.
zimmer-group.com:
• CSR series
Please contact Zimmer Customer Service if you have any questions.
5.2 Type plate
A type plate is attached to the housing of the product (see
the image on the right for an example). The article number
andtheconrmationnumberareshownonthetypeplate.
Theconrmationnumberisassignedtotheproject.This
ensuresunambiguousandconsistentclassicationinthe
event of an update or an overhaul.
ÖExample of an article number: dl
ÖExampleofaconrmationnumber:dm
XXX
XX-XXXXXX
dl
dm
INFORMATION
Pleasestatetheconrmationnumberintheeventofdamageoracomplaint.
Please contact Zimmer Customer Service if you have any questions.

INSTALLATION AND OPERATING INSTRUCTIONS: Collision protection, pneumatic, CSR series
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau,Germany •[phone] • [phone] •www.zimmer-group.com
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EN / 2020-09-15DDOC00267 / b
6 Function
Thepistonismovedintoitshomepositionbyllingtheinternalpneumaticcylinder.Itcanbepressedoutofthispositionby
externalforces.Airowsoverthepressuremembraneintothesurroundingsduringthisprocess.
This causes a pressure drop inside the pneumatic cylinder. The pressure drop actuates the integrated proximity switch.
The signal from the integrated proximity switch can be used as an EMERGENCY STOP signal for the machine.
Afteractivation,thecompensatingangemustbeputintothehomepositionbyhand.
Thehomepositionisreachedoncethetrianglesappliedonthehousingandthecompensatingangealignwitheachother
again.
1Robotange Fig. 1: CSR series collision protection
Fig. 2: Cutaway view of the CSR series collision protection
1
2
5
6
7
3
4
8
2Power supply
3Pressure differential switch
4Sensors
5Drive
6Force transmission
7Connectingange
8Overload recognition
7 Technical data
INFORMATION
For technical data, please refer to our website at www.zimmer-group.com:
• Collision protection
Thisdatavarieswithintheseries,dependingonthespecicdesign.
Please contact Zimmer Customer Service if you have any questions.

INSTALLATION AND OPERATING INSTRUCTIONS: Collision protection, pneumatic, CSR series
7
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
EN / 2020-09-15DDOC00267 / b
8 Installation
8.1 General installation information
WARNING
Risk of injury in case of unexpected movement of the machine or system into which the product is to be installed.
►Switch off the power supply to the machine before all work.
►Secure the machine against being switched on unintentionally.
►Check the machine for any residual energy.
CAUTION
Risk of injury in the event of unexpected movement of the product when the power supply is connected.
►Switch off the power supply to the product before all work.
►Secure the power supply against being switched on unintentionally.
►Check the power supply for any residual energy.
Non-compliance may result in severe injuries!
Spring-loaded components can jump out when installing or uninstalling the device.
ÖRisk of injury
NOTICE
Switch off the power supply before any assembly, installation or maintenance work.
Theproductmustbeinstalledonasuitablemountingsurfaceinaccordancewiththeatnessspecications.
ÖPermissibleatnessimperfection:0.03
• Mounting screws are included in the scope of delivery.
• Strengthclassofthemountingscrews≥8.8(DINENISO4762)
• Observe the tightening torque of the mounting screws.
ÖZimmer GmbH recommends verifying the permitted load-carrying capacity of the required screw connections in
accordance with VDI 2230.
• The exact installation positions can be found on the technical data sheet on our website.

INSTALLATION AND OPERATING INSTRUCTIONS: Collision protection, pneumatic, CSR series
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau,Germany •[phone] • [phone] •www.zimmer-group.com
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EN / 2020-09-15DDOC00267 / b
8.2 Installing the product on the robot
The following work steps must be observed during instal-
lation:
►Removetherobotangefromthecollisionprotection.
►Positiontherobotangeontherobotarmusingthe
straight pin 9.
►Mounttherobotangeontherobotusingthe
mounting screws bl.
►Reinstallthecollisionprotectionontherobotange
using the mounting screws bm.
bm
bl
9
8.3 Installing the custom application
Before installing the custom application, check whether
its weight and dimensions are suitable for the selected
collision protection.
To install the custom application, perform the following
work steps:
►Position the custom application on the connecting
ange7using the straight pin hm.
►Secure the custom application using cylinder
screwshnwith a strength class of 8.8.
7
hm
hn

INSTALLATION AND OPERATING INSTRUCTIONS: Collision protection, pneumatic, CSR series
9
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
EN / 2020-09-15DDOC00267 / b
8.4 Installing the power supply and sensor
►Insert the screw connection bninto the designated
connectors.
The inductive proximity switch 4generates a signal that
can be evaluated to recognize an overload.
This can be used to initiate an automatic emergency-stop
on the system.
►Inserttheinductiveproximityswitchintotheholdergn.
►Clamp the proximity switch using the screws gmto a
maximum of 0.8 Nm.
►Attach the connecting cable to the sensor and screw it
into place.
ÖThe respective connecting cables are available as
accessories.
bn
gn
gm
4
8.5 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: Collision protection, pneumatic, CSR series
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau,Germany •[phone] • [phone] •www.zimmer-group.com
10
EN / 2020-09-15DDOC00267 / b
9 Maintenance
The CSR series product is maintenance-free.
The maintenance-free period may shorten under the following circumstances:
• Operation with compressed air that does not comply with DIN ISO 8573-1 [2:4:1]
• Dirty environment
• Improperuseandusethatdoesnotcomplywiththepowerspecications
• Observe the ambient temperature; lubricants harden faster!
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 using Zimmer Customer Service for maintenance and the replacement of seals.
Dismantling and reassembling the product without authorization may result in complications, as special installation
equipment is required in some cases.
Zimmer GmbH shall not be liable in the event of unauthorized dismantling and reassembling of the product or in the event
of any malfunction or damage resulting from this.
10 Accessories/scope of delivery
INFORMATION
If any accessories not sold or authorized by Zimmer Group are used, the function of the product cannot be
guaranteed.ZimmerGroupaccessoriesarespecicallytailoredtotheindividualproducts.
Optional accessories and those included in the scope of delivery can be found at www.zimmer-group.com.
11 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 unintentional movements can occur. Before commissioning the machine after transport, check all power
and communication connections as well as all mechanical connections.
►If the product is stored for an extended period, the following points are to be observed:
• Keep the storage location as dust-free and dry as possible.
• Avoidtemperatureuctuations/observeandadheretothetemperaturerange.
• Avoid wind/drafts/water condensation formation.
• 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 of the components.
►Remove all foreign substances.
►Properly remove potential corrosion spots.
►Close electrical connections using suitable covers.
12 Decommissioning and disposal
INFORMATION
When the product reaches the end of its operational phase, it can be completely disassembled and disposed
of. Completely disconnect the product from the power supply. The product can be disassembled and properly
disposed of according to material groups. When disposing of it, observe the locally applicable environmental
regulations and codes and regulations for disposal.

INSTALLATION AND OPERATING INSTRUCTIONS: Collision protection, pneumatic, CSR series
11
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
EN / 2020-09-15DDOC00267 / b
13 Declaration of Incorporation
In terms of the EU Machinery Directive 2006/42/EC (Annex II 1 B)
Name and address of the manufacturer:
Zimmer GmbH
77866 Rheinau, Germany, Im Salmenkopf 5
[phone]
[phone]
www.zimmer-group.com
We hereby declare that the incomplete machines described below
Product designation: Collision protection, pneumatic
Type designation: CSR series
conform to the requirements of the Machinery Directive, 2006/42/EC, Article 2g, Annex VII.b – Annex II.b, in its design and
the version we put on the market.
Basic health and safety requirements:
No. 1.1.2, No. 1.1.3, No. 1.1.5, No. 1.3.1, No. 1.3.2, No. 1.3.4, No. 1.3.7, No. 1.5.1, No. 1.5.3, No. 1.5.4, No. 1.6.4, No. 1.7.1,
No.1.7.3.
The following harmonized standards have been used:
DIN EN ISO 12100:2011-03 Safety of machinery – General principles for design – Risk assessment and
risk reduction
DIN EN ISO 13849-1 Safety of machinery – Safety-related parts of control systems
DIN EN ISO 13849-2 Safety-related parts of control systems
WealsodeclarethatthespecictechnicaldocumentswereproducedinaccordancewithAnnexVIIPartBofthisDirective.
We undertake to provide the market supervisory bodies with electronic versions of special documents for the incomplete
machine through our documentation department, should they have reason to request them.
The incomplete machine may only be commissioned if it has been ascertained, if applicable, that the machine or
system in which the incomplete machine is to be installed satises the requirements of Directive 2006/42/EC on
Machinery and an EC Declaration of Conformity has been drawn up in accordance with Annex II 1 A.
A full list of applied standards can be obtained from the manufacturer.
Authorized representative for the compilation of
relevant technical documents
Kurt Ross See manufacturer's address Rheinau, Germany, 2020-09-15 Martin Zimmer
First name, last name Address (Place and date of issuance) (Legally binding signature)
Managing Partner

INSTALLATION AND OPERATING INSTRUCTIONS: Collision protection, pneumatic, CSR series
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau,Germany •[phone] • [phone] •www.zimmer-group.com
12
EN / 2020-09-15DDOC00267 / b