Zimmer DVR Series User manual

INSTALLATION AND
OPERATING
INSTRUCTIONS
Rotary distributor
DVR series
DDOC00222
THE KNOW-HOW FACTORY

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
5 Product description ..................................................................................................................................................................... 6
5.1 Forces and torques..............................................................................................................................................................................................................6
5.2 Type plate .............................................................................................................................................................................................................................6
6 Functional description ................................................................................................................................................................. 7
7 Technical data .............................................................................................................................................................................. 8
8 Accessories/scope of delivery ................................................................................................................................................... 8
9 Transportation/storage/preservation......................................................................................................................................... 8
10 Installation .................................................................................................................................................................................... 9
10.1 Installing the product.........................................................................................................................................................................................................10
10.2 Installing the energy supply ..............................................................................................................................................................................................12
10.2.1 Installing the wiring..............................................................................................................................................................................................12
10.2.2 Installing the pneumatic system.........................................................................................................................................................................14
10.3 Connecting the sealing air ................................................................................................................................................................................................14
10.4 Attaching the torque support arm ....................................................................................................................................................................................15
10.5 Installing accessories ........................................................................................................................................................................................................15
11 Maintenance............................................................................................................................................................................... 16
12 Decommissioning/disposal ...................................................................................................................................................... 16
13 RoHS declaration....................................................................................................................................................................... 17
14 REACH declaration.................................................................................................................................................................... 17
15 Declaration of Incorporation ..................................................................................................................................................... 18
INSTALLATION AND OPERATING INSTRUCTIONS: DVR
DDOC00222 / g EN / 2022-01-13
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.
INSTALLATION AND OPERATING INSTRUCTIONS: DVR
DDOC00222 / g EN / 2022-01-13
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

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ttedtoindustrialmachinesandisusedtohold,transportandstoreworkpieces.
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.
►Note that, due to the spring tension, you should exercise increased caution when uninstalling products with
integrated springs.
INSTALLATION AND OPERATING INSTRUCTIONS: DVR
DDOC00222 / g EN / 2022-01-13
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.
►Operate the product only in compliance with the associated installation and operating instructions.
►Operate the product only when it is in a technical condition that corresponds to the guaranteed parameters
and operating conditions.
ÖZimmer GmbH shall accept no liability for any damage caused by improper use. The operator bears sole
responsibility.
The product is designed for forwarding electric and pneumatic energies through rotating connections.
The product is designed exclusively for operation within the parameter limits and operating conditions stipulated in the
orderconrmation.
The product is designated for use in closed facilities.
Direct contact with perishable goods/food is not permitted.
4 Personnel qualication
Installation, commissioning and maintenance may only be performed by trained specialists. These persons must have read
and understood the installation and operating instructions in full.
5 Product description
5.1 Forces and torques
INFORMATION
►Youcanndtheinformationinthetechnicaldatasheetonourwebsite.
►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. 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
INSTALLATION AND OPERATING INSTRUCTIONS: DVR
DDOC00222 / g EN / 2022-01-13
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

7
6 Functional description
The products are designed to be media exchangers.
The compact design reduces the torque loads for the handling system to a minimum.
The product avoids interference contours and thus prevents cable breaks, damage or tears caused by exposed wires.
Allcurrentsfromnecurrentsupto250Vandamaximumof6Acanbetransmittedreliably.
Inside,thecontactsontheslipringallowforhighexibilityinelectricaltransmission.
The housing acts as a stator by means of the torque support arm. The energy/media to be transferred is brought in here.
Therobotangeandtheconnectingangeonthetoolaretherotatingelements.
ThestructuraldesignoftheconnectingangeisbasedonthespecicationsfromDINENISO9409-1.
1Pneumatic feed-through
2Sealing air connection
3Connectingangeontherobot
4Energy and data transmission
5Torque support
6Hoseless air connection to the tool
changer
7Connectingangeonthetool
8Case
3
4
1
2
6
7
8
5
INSTALLATION AND OPERATING INSTRUCTIONS: DVR
DDOC00222 / g EN / 2022-01-13
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

8
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.
8 Accessories/scope of delivery
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/observeandadheretothetemperaturerange.
►Avoid wind/drafts/water condensation formation.
►Cover the product with a weatherproof, tear-resistant foil to prevent dust.
►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: DVR
DDOC00222 / g EN / 2022-01-13
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

9
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.
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.
NOTICE
Non-compliance may result in material damage.
Malfunctionsandunitdamageifthetoolangeandhousingaredisconnectedfromeachother.
►Makesurethatthetoolangeandhousingarenotdisconnectedfromeachotherduringdisassembly.
►Ifthetoolangeandhousingareaccidentallydisconnected,observethefollowinginstructions.
►Do not touch the electrical sliding contacts in the interior.
►Carefullyreconnectthetoolangeandhousing.
INFORMATION
Requirements for the mounting surface:
• Permissible unevenness: 0.03 mm
Further installation information:
• The mounting screws are not included in the scope of delivery.
• Strength class of the mounting screws is at least 8.8 (DIN EN ISO 4762)
• Screw-in depth in accordance with DIN EN ISO 9409-1
►Observe the tightening torque of the mounting screws.
►Verify the permitted load capacity of the required screw connections in accordance with VDI 2230.
INSTALLATION AND OPERATING INSTRUCTIONS: DVR
DDOC00222 / g EN / 2022-01-13
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

10
10.1 Installing the product
INFORMATION
Whenselectingtheinstallationsizeanddesignoftheproduct,thetypeofconnectingangeontherobotin
accordancewithDINENISO9409-1andthefunctionstobeimplementedonthetoolarethedecidingfactors.
INFORMATION
More installation information for the central screw:
• Strength class 12.9 (DIN EN ISO 4762)
• Tightening torque in accordance with VDI 2230:2015 Table A1
• Friction value 0.14
Theproductisinstalledbetweentherobotangeandthetool.Installationbeginsontherobotange.Thetoolortool
changer can then be installed on the product.
►Remove the central screw.
3
9
bm
bl
►Removetherobot-sideconnectingange.
►Insertthestraightpinintothedesignatedtontherobot-side
connectingange.
►Positiontherobot-sideconnectingangeontotherobotangeby
using the straight pin.
►Installtherobot-sideconnectingangeontotherobotangebyusing
the mounting screws.
►Reinstallthehousingontotherobot-sideconnectingangebyusing
the central screw.
3Connectingangeontherobot
9Straight pins
bl Mounting screw
bm Centering plate
INSTALLATION AND OPERATING INSTRUCTIONS: DVR
DDOC00222 / g EN / 2022-01-13
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

11
►Insertthestraightpinintothedesignatedtonthetool-side
connectingange.
bn
bo
7
►Positionthetoolonthetool-sideconnectingangebyusingthe
straight pin.
►Usethemountingscrewstomountthetoolonthetoolange.
7Connectingangeonthetool
bn Straight pins
bo Mounting screw
INSTALLATION AND OPERATING INSTRUCTIONS: DVR
DDOC00222 / g EN / 2022-01-13
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

12
10.2 Installing the energy supply
10.2.1 Installing the wiring
The connection with the pins is located on the
stator and the connection with the sockets is
located on the rotor.
►Connect the power supply cable to the
control system of the product.
10.2.1.1 Pin assignment of DVR40I4 and DVR50I4
Pin Socket
1
2
3
4
⬌3
4
1
2
1⬌1
2⬌2
3⬌3
4⬌4
10.2.1.2 Pin assignment of DVR63I6 and DVR80I6
Pin Socket
54321
9876
⬌
1
9
5432
876
1⬌1
2⬌2
3⬌3
4⬌4
5⬌5
6⬌6
7 n. c. 7
8 n. c. 8
9 n. c. 9
INSTALLATION AND OPERATING INSTRUCTIONS: DVR
DDOC00222 / g EN / 2022-01-13
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

13
10.2.1.3 Pin assignment of DVR100I4 and DVR100I8
Pin Socket
54321
9876
⬌
1
9
5432
876
1⬌1
2⬌2
3⬌3
4⬌4
5⬌5
6⬌6
7⬌7
8⬌8
9 n. c. 9
10.2.1.4 Pin assignment of DVR125I4, DVR125I8, DVR160I4 and DVR160I8
Pin Socket
54321 6 7 8
9 10 11 12 13 14 15
⬌
54 3 2 1 678
9101112131415
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
INSTALLATION AND OPERATING INSTRUCTIONS: DVR
DDOC00222 / g EN / 2022-01-13
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

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10.2.2 Installing the pneumatic system
INFORMATION
The number of integrated air transmitters varies within the series.
►Insertthescrewttingsintotheprovidedconnections.
bp
6
bq
In addition, there is the option of a hoseless pneumatic feed-through to
thefrontofthetoolange.Ifthisconnectionisused,theoutputsonthe
outeredgeofthetoolangemustbesealed.
Theassignmentoftheinputsandoutputscanbeidentiedby
numbering. Labels for numbering are included in the scope of delivery.
6Hoseless air connection to the tool changer
bp Outer edge of housing
Robot input
bq Outeredgeoftoolange
Tool output
NOTICE
►Close off unused connections using suitable dummy plugs.
►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].
10.3 Connecting the sealing air
NOTICE
Non-compliance may result in material damage.
Damage to the electronic transmission elements is possible if the wrong compressed air is used.
►Use compressed air in accordance with DIN ISO 8573-1 [2:4:1].
p max = 0.5 bar
2
2Sealing air connection
INSTALLATION AND OPERATING INSTRUCTIONS: DVR
DDOC00222 / g EN / 2022-01-13
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

15
10.4 Attaching the torque support arm
NOTICE
Non-compliance may result in material damage.
Thetorquesupportarmisdesignedsothatlateraltorquesarenotappliedtothemiddlepartwithoatingbearing.
►Implement the torque support arm as shown.
Exchangingthestandardtorquesupportarmfora2-pointscrewttinginthemiddlepartmaydamagetheseals
and the inner electric slip ring system.
INFORMATION
The pin must be manufactured according to DIN ISO 2768 - fH.
►Calculate the pin diameter for the torque support arm using the dimensions from the dimensional drawing on
the data sheet.
►Arrange the pin of the torque support arm
parallel to the turning axis or casing surface
of the product.
►Maintain a parallelism tolerance of
0.1 mm.
br
5
bs
5Torque support
br Specicationforpindiameter
bs Pin
10.5 Installing accessories
NOTICE
Before installing an accessory, make sure it is suitable for use with the selected variant.
►Youcanndinformationonourwebsite.
►Please contact Zimmer Customer Service if you have any questions.
INSTALLATION AND OPERATING INSTRUCTIONS: DVR
DDOC00222 / g EN / 2022-01-13
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

16
11 Maintenance
CAUTION
Material damage resulting from blowing out with compressed air
Blowing out the product with compressed air can cause malfunctions and pose a risk of accidents.
►Never purge the product with compressed air.
CAUTION
Material damage caused by liquid and solvent-based cleaners
Liquid and solvent-based cleaning agents can cause malfunctions and pose a risk of accidents.
►Do not clean the product with any cleaning agents that are liquid or contain solvents.
INFORMATION
Non-compliance may result in material damage.
If the product is constantly subjected to an alternating direction of rotation, the maximum number of rotations will
no longer be reached.
The actual service life depends on the following factors:
• Speed
• Changes in direction of rotation
• Environmental conditions (humidity, temperature)
• Handling weight
• Electrical voltage and amperage
• Continuous operation with sealing air and its quality
Maintenance-free operation of the product is guaranteed for up to 10 million cycles.
The maintenance interval may be shortened under the following circumstances:
• Dirty environment
• Improperuseandusethatdoesnotcomplywiththepowerspecications.
• Ambient temperature is too high.
►Even though the product is maintenance-free as mentioned above, perform a regular visual inspection to check for any
corrosion, damage or contamination.
►Have maintenance work be performed by Zimmer Customer Service whenever possible.
ÖDismantling and reassembling the product without authorization may result in complications, as special installation
equipment is required in some cases. Zimmer GmbH accepts no liability for any resulting malfunctions or damage.
12 Decommissioning/disposal
INFORMATION
When the product reaches the end of its operational phase, 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.
NOTICE
Continuous operation with sealing air
►Have the product removed and relubricated by Zimmer Customer Service at least every 6 months.
INSTALLATION AND OPERATING INSTRUCTIONS: DVR
DDOC00222 / g EN / 2022-01-13
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

17
13 RoHS declaration
in terms of the EU Regulation 2011/65/EU
Name and address of the manufacturer:
Zimmer GmbH
Im Salmenkopf
77866 Rheinau, Germany
[phone]
[email protected]
www.zimmer-group.com



We hereby declare that the incomplete machine described below
Product designation: Rotary distributor
Type designation: DVR series
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 the
compilation of relevant technical
documents
(Place and date of issuance) Martin Zimmer
(Legally binding signature)
Managing Partner
14 REACH declaration
In terms of the EC Regulation 1907/2006
Name and address of the manufacturer:
Zimmer GmbH
Im Salmenkopf
77866 Rheinau, Germany
[phone]
[email protected]
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 the
compilation of relevant technical
documents
(Place and date of issuance) Martin Zimmer
(Legally binding signature)
Managing Partner
INSTALLATION AND OPERATING INSTRUCTIONS: DVR
DDOC00222 / g EN / 2022-01-13
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com

18
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
77866 Rheinau, Germany
[phone]
[email protected]
www.zimmer-group.com



We hereby declare that the incomplete machine described below
Product designation: Rotary distributor
Type designation: DVR 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:
Nr.1.1.2, Nr.1.1.3, Nr.1.1.5, Nr.1.3.2, Nr.1.3.4, Nr.1.3.7, Nr.1.5.3, Nr.1.5.4, Nr.1.5.8, Nr.1.6.4, Nr.1.7.1, Nr.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.
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.
Kurt Ross Rheinau, Germany, 2021-03-25
Authorized representative for the
compilation of relevant technical
documents
(Place and date of issuance) Martin Zimmer
(Legally binding signature)
Managing Partner
INSTALLATION AND OPERATING INSTRUCTIONS: DVR
DDOC00222 / g EN / 2022-01-13
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • [phone] • www.zimmer-group.com