Zimmer HRC-03 Series User manual

INSTALLATION AND
OPERATING
INSTRUCTIONS
HRC-03 series
Gripper, electric
DDOC00268
THE KNOW-HOW FACTORY
www.zimmer-group.com

INSTALLATION AND OPERATING INSTRUCTIONS: 2-jaw parallel gripper, electric, HRC-03 series
2
DDOC00268 / g EN / 2020-01-10
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
Parameter explanation (glossary)
Parameter Explanation
ControlWord
The gripper is controlled with the "ControlWord".
The "ControlWord" is bit-exclusive, which means that only one bit at a time can be
active in the "Word". The value "ZERO" is also permitted.
DeviceMode The "DeviceMode" is used to select gripping proles as well as the additional help
modes in the gripper.
Workpiece No. Using this parameter, workpiece recipes stored in the gripper can be selected or
saved.
TeachPosition The "TeachPosition" is the actual workpiece position.
WorkPosition The "WorkPosition" is the inner jaw position on the gripper. Depending on the
application, for example with internal grippers, this can also be the standby position.
GripForce The "GripForce" parameter is used to congure the gripping force.
PositionTolerance This is the tolerance window for the "TeachPosition", "BasePosition" and
"WorkPosition". The value of the parameter acts in both directions.
BasePosition The "BasePosition" is the outer "JawPosition". Depending on the gripper prole, this
can also be a work position!
ShiftPosition The "ShiftPosition" is a switching position between pre-positioning and gripper
movement.
StatusWord In its bits, the "StatusWord" supplies the most important information about the status
of the gripper back to the control system.
Diagnosis If an error should occur, the "Diagnosis" outputs a diagnostic code which can be
compared with the error list.
ActualPosition The value of the current position of the gripper [1/100 mm].
Error Fault, error message
DIR Direction/24V cable connection - Depending on the gripper, this signal is used to
move the gripper.
Teach/Adjust
Program/Congure
Using this signal, depending on the gripper type, the current position of the gripper
jaws can be taught in as the new workpiece position. "Adjust" is used as a command
to dene the reachable end positions of the gripper jaws.
GND Abbreviation for ground connection
Oset Correction value
Traversing routine Dened procedure for movement of the gripper jaws
Travel path Path on which the gripper jaws travel
LED Light-emitting diode
HRC Human-robot collaboration

INSTALLATION AND OPERATING INSTRUCTIONS: 2-jaw parallel gripper, electric, HRC-03 series
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Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
DDOC00268 / gEN / 2020-01-10
Contents
1. Supporting documents.......................................................................................................................................................5
2. Safety notice ........................................................................................................................................................................5
3. Proper use............................................................................................................................................................................6
4. Personnelqualication .......................................................................................................................................................6
5. Product description.............................................................................................................................................................6
5.1 Possible applications........................................................................................................................................................................................6
5.2 Forces and torques...........................................................................................................................................................................................6
5.3 Type plate .........................................................................................................................................................................................................7
5.4 Criteria for use in collaborative applications .................................................................................................................................................. 7
6. Function ...............................................................................................................................................................................8
6.1 Electricalspecications....................................................................................................................................................................................8
6.2 LED display .......................................................................................................................................................................................................9
6.2.1 “IO-Link” LED display ...................................................................................................................................................................... 9
6.2.2 LED display “digital + integrated analog sensing” ........................................................................................................................9
6.3 Veriedconguration........................................................................................................................................................................................9
6.4 Protection classes.............................................................................................................................................................................................9
6.5 Technical data .................................................................................................................................................................................................10
6.6 Self locking mechanism .................................................................................................................................................................................10
7. Installation..........................................................................................................................................................................10
7.1 Safety notice....................................................................................................................................................................................................10
7.2 Installation of the mechanical system ...........................................................................................................................................................10
7.2.1 General installation information....................................................................................................................................................10
7.2.2 “IO-Link” installation .....................................................................................................................................................................11
7.2.3 “IO-Link” installation with adapter plate ......................................................................................................................................12
7.2.4 “Digital + integrated analog sensing” installation .......................................................................................................................13
7.2.5 “Digital” installation .......................................................................................................................................................................14
7.3 Installation of the electrical system................................................................................................................................................................15
7.3.1 Installation of the wiring ................................................................................................................................................................15
7.3.2 “Digital” and “Digital + integrated analog sensing” ....................................................................................................................15
7.3.3 “IO-Link” installation ......................................................................................................................................................................16
7.4 Static charge ...................................................................................................................................................................................................16
7.5 Heat dissipation...............................................................................................................................................................................................16
7.6 Installation of accessories ..............................................................................................................................................................................16
8. Commissioning..................................................................................................................................................................17
8.1 “Analog” and “Digital” commissioning..........................................................................................................................................................17
8.1.1 Restart “Analog“ and “Digital“......................................................................................................................................................17
8.1.2 “Analog” and “Digital” switching sequence.................................................................................................................................17
8.2 IO-Link commissioning ...................................................................................................................................................................................18
8.2.1 Process data...................................................................................................................................................................................18
8.2.2 IODD import ...................................................................................................................................................................................19
8.3 “Handshake” data transfer method...............................................................................................................................................................19
8.4 Parameter ........................................................................................................................................................................................................20
8.4.1 “ControlWord” parameter .............................................................................................................................................................20
8.4.2 “DeviceMode” parameter..............................................................................................................................................................21
8.4.3 “WorkpieceNo” parameter............................................................................................................................................................21
8.4.4 “PositionTolerance” parameter .....................................................................................................................................................22
8.4.5 “GripForce” parameter ..................................................................................................................................................................22
8.4.6 “TeachPosition” parameter ...........................................................................................................................................................23
8.4.7 “StatusWord” parameter ...............................................................................................................................................................23
8.4.8 “Diagnosis” parameter ..................................................................................................................................................................24
8.4.9 “ActualPosition” parameter ...........................................................................................................................................................25
8.5 “Cold boot”......................................................................................................................................................................................................25

INSTALLATION AND OPERATING INSTRUCTIONS: 2-jaw parallel gripper, electric, HRC-03 series
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DDOC00268 / g EN / 2020-01-10
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
8.6 Minimum travel path .......................................................................................................................................................................................25
8.7 “Easy Startup”.................................................................................................................................................................................................26
8.7.1 “Easy Startup” HRC-03 series ......................................................................................................................................................26
8.8 Starting gripping movement ..........................................................................................................................................................................27
8.9 Repeated movement in the same direction..................................................................................................................................................27
8.9.1 “Save recipe”..................................................................................................................................................................................28
8.10 Recipe examples “Load recipe” ....................................................................................................................................................................29
9. Operation ...........................................................................................................................................................................30
9.1 “Analog” and “Digital + integrated analog sensing” ...................................................................................................................................30
9.1.1 “Analog” and “Digital + integrated analog sensing” emergency release .................................................................................30
9.1.2 “Analog” and “Digital + integrated analog sensing” adjustable gripping force .......................................................................31
9.2 “IO-Link” ..........................................................................................................................................................................................................32
9.2.1 “IO-Link” emergency release .......................................................................................................................................................32
9.2.2 “IO-Link” adjustable gripping force ..............................................................................................................................................33
10.Gripping force charts ........................................................................................................................................................33
11.Troubleshooting.................................................................................................................................................................34
12.Maintenance ......................................................................................................................................................................36
13.Accessories/scope of delivery.........................................................................................................................................36
14.Transportation/storage/preservation ..............................................................................................................................36
15.Decommissioning and disposal.......................................................................................................................................36
16.RoHS declaration ..............................................................................................................................................................37
17.REACH declaration ...........................................................................................................................................................37
18.Declaration of Incorporation.............................................................................................................................................38
19.Declaration of Conformity.................................................................................................................................................39

INSTALLATION AND OPERATING INSTRUCTIONS: 2-jaw parallel gripper, electric, HRC-03 series
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Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
DDOC00268 / gEN / 2020-01-10
1. Supporting documents
NOTICE:
Read through the installation and operating instructions carefully before installing the product!
The installation and operating instructions contain important notes for your personal safety. They
must be read and understood by all persons who work with or handle the product during any phase
of the product life time.
The documents listed below are available for download on our website.
Öwww.zimmer-group.com
Only those documents currently available on the website are valid.
• Catalogs, drawings, CAD data, performance data
• Information on accessories
• Detailed installation and operating instructions
• Technical data sheets
• General Terms and Conditions of Business, including warranty information
2. Safety notice
CAUTION:
Non-compliance may result in severe injuries!
1. Installation,commissioning,maintenanceandrepairsmayonlybeperformedbyqualiedspecialistsin
accordance with these installation and operating instructions.
2. Thegripperisstate-of-the-art.Itisttedtoindustrialmachinesandisusedtoholdworkpieces.Thefollowingare
examples of situations in which the gripper may pose a hazard:
• The gripper is not properly installed, used or maintained.
• The gripper is not used for its intended purpose.
• Local regulations (legislation, ordinances, guidelines), such as the EC Machinery Directive, accident
prevention regulations and the installation and operating instructions, are not observed.
3. The gripper may be used only in accordance with its proper use and technical data. Zimmer GmbH shall accept no
liability for any damage caused by improper use.
4. Any use other than the intended use requires written approval from Zimmer GmbH.
5. Make sure that the power cables are disconnected before you install, modify, maintain or repair the gripper.
6. In case of maintenance, conversion or expansion work, remove the gripper from the machine and perform the work
outside the danger zone.
7. When commissioning or testing, make sure that the gripper cannot be activated by mistake.
8. Modicationstothegripper,suchasaddingdrilledholesorthreads,maybemadeonlywithpriorapprovalfrom
Zimmer GmbH.
9. Thespeciedmaintenanceintervalsaretobeobserved;alsorefertothe“Maintenance”section.Whenthegripper
is used under extreme conditions, the maintenance interval must be adapted depending on the extent of the
contamination. Please contact our hotline for this purpose.
10.Use of the gripper under extreme conditions, such as aggressive liquids and abrasive dusts, is subject to prior
approval from Zimmer GmbH.
11.Thesuitabilityofthegripperforcollaborativeusecanonlybeveriedwhileusinggripperngersinstalledinfactory
condition.Ifdifferentgripperjawsareusedoriftheoriginalgripperjawsaremodied,compliancewiththe
maximumforceandpressurevaluespermittedforcollaborativeoperationmustbeveriedonceagain.
12.Do not reach into the operational range of the gripper!

INSTALLATION AND OPERATING INSTRUCTIONS: 2-jaw parallel gripper, electric, HRC-03 series
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DDOC00268 / g EN / 2020-01-10
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
3. Proper use
NOTICE:
The gripper is to be used only in its original state with its original accessories, without any
unauthorizedchangesandwithinthescopeofitsdenedparametersofuse.
Zimmer GmbH shall accept no liability for any damage caused by improper use.
Useoutsideofthedenedparametersisnotpermitted.Unauthorizedelectricalormechanicalmodicationsmustnot
be made.
The gripper is designed exclusively for electric operation using a supply voltage of 24 VDC.
Thegripperisusedasdenedunder“Properuse”inenclosedroomsfortemporarilygripping,handlingandholding
workpieces in human-robot collaboration.
The gripper is not suitable for clamping workpieces during a machining process.
Direct contact with perishable goods/food is not permitted.
4. Personnel qualication
Installation,commissioningandmaintenancemayonlybeperformedbyqualiedpersonnel.Thesepersonnelmust
have read and understood the installation and operating instructions in full.
5. Product description
NOTICE:
To ensure that the gripper jaws do not get deformed, care must be taken to ensure that the
congurationofthegrippingforceandtheselectionofthegripperngerlengthiscorrect.
Anincorrectcongurationorselectioncanleadtomalfunction.
CAUTION:
Reduction of gripping force
Reducethegrippingforceofthegripperwhengrippingexiblecomponents.
A reduced gripping force can lead to material damage or injury to personnel, because the
components that are being gripped can no longer be securely gripped and transported.
5.1 Possible applications
Inside gripping:
The gripper can be used for inside
gripping.
Outside gripping:
The gripper can be used for outside
gripping.
5.2 Forces and torques
INFORMATION:
For information on forces and torques, please visit our website.
Zimmer Customer Service is available to provide you assistance if you have any further questions.
Inside grippingOutside gripping

INSTALLATION AND OPERATING INSTRUCTIONS: 2-jaw parallel gripper, electric, HRC-03 series
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Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
DDOC00268 / gEN / 2020-01-10
5.3 Type plate
There is a type plate attached to the housing of the gripper.
The serial number and the article number are shown on this type plate.
• The serial number ensures that the unit has an unambiguous, continuous
classicationintheeventofanupdateoranoverhaul.
• You should assign the serial number to your project when possible.
ÖExample: Serial number 01-12345678
INFORMATION:
Please state the serial number in the event of damage or a complaint.
Zimmer Customer Service is available to provide you assistance if you have any further questions.
5.4 Criteria for use in collaborative applications
The criteria listed below are the basis for the suitability of the
gripper for use in collaborative applications:
ÖSeeadjacentillustration,gure3and 4.
• The gripper has been designed in accordance with the
specicationsofISO/TS15066.
• The power of the motor in combination with the
transmission design and the pre-assembled gripper jaws
isnotsu󹱺cienttogenerateagrippingforce>140N
upon vulnerable areas of the body. The gripping forces
generatedwhengrippingsoftobjectsaresignicantly
reduced, since the amount of dynamic force is lowered.
Compliance with the maximum permitted gripping force
hasbeenveriedusingasuitablemeasuringinstrument.
• The gripper is engineered to be inherently safe and is
designed with rounded edges and shapes that prevent
crushing and shearing points from being created.
3 4
1 2
Automation cell Coexistence
Cooperation Collaboration
Separated workspaces Presence detection
Shared workspacesZones of action

INSTALLATION AND OPERATING INSTRUCTIONS: 2-jaw parallel gripper, electric, HRC-03 series
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DDOC00268 / g EN / 2020-01-10
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6. Function
Thegripperngersoftheparallelgripperarearrangedparalleltoeachotherontwoopposingguiderailsandcanbe
moved relative to each other. The force of the motor is transmitted over a worm drive. A pinion and a rack generate the
movement of the gripper jaws and synchronize these movements.
Despiteitssmallinstallationspace,thegripperisqualiedforthegrippingofawiderangeofformtandfrictionalt
parts and can easily be integrated into the existing control system. The gripping force can be adapted optimally to the
workpiece conditions.
You can optionally adjust the gripping force onto the workpiece by means of the integrated potentiometer or over the
control system via IO-Link. The gripper can be controlled like a valve via I/O ports or via IO-Link. Both versions are easy
to integrate into the control system.
6.1 Electrical specications
INFORMATION:
Forinformationonelectricalspecications,pleasevisitourwebsite.
Thisdatavarieswithintheseriesdependingonthespecicdesign.
Zimmer Customer Service is available to provide you assistance if you have any further questions.
1Control
2Mounting and positioning
3LED display/plastic ring
4Gripper jaws

INSTALLATION AND OPERATING INSTRUCTIONS: 2-jaw parallel gripper, electric, HRC-03 series
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Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
DDOC00268 / gEN / 2020-01-10
6.2 LED display
6.2.1 “IO-Link” LED display
ThecolorsoftheLEDringreectthestatusofthegripper.
The LED ring enables a 360° status display.
Status Function
On continuously "TeachPosition"
Flashing Currently not assigned
On continuously "BasePosition"
Flashing Currently not assigned
On continuously The gripper has a fault
Flashing No IO-Link connection available
On continuously Gripper is in undened position
Flashing Currently not assigned
6.2.2 LED display “digital + integrated analog sensing”
6.3 Veried conguration
INFORMATION:
Forinformationabouttheveriedconguration,pleasevisitourwebsite.
Zimmer Customer Service is available to provide you assistance if you have any further questions.
6.4 Protection classes
NOTICE:
The gripper achieves protection class IP40 in all mounted positions of installation.
cl Power/communication
cm Error

INSTALLATION AND OPERATING INSTRUCTIONS: 2-jaw parallel gripper, electric, HRC-03 series
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DDOC00268 / g EN / 2020-01-10
Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
6.5 Technical data
INFORMATION:
For information on technical data, please visit our website.
Thisdatavarieswithintheseriesdependingonthespecicdesign.
Zimmer Customer Service is available to provide you assistance if you have any further questions.
6.6 Self locking mechanism
INFORMATION:
The gripper has a mechanical self locking mechanism to ensure that the workpiece remains held by
the gripper in the event of power supply loss or failure (such as an emergency stop).
Zimmer Customer Service is available to provide you assistance if you have any further questions.
7. Installation
7.1 Safety notice
NOTICE:
Switch off the energy supply for the electronics before any assembly, installation or maintenance
work.
►Electronics may get damaged.
CAUTION:
Switch off the energy supply for the electronics before any assembly, installation or maintenance
work.
►Injuries are possible.
WARNING:
Risk of injury in case of unexpected movement of the machine or system into which the gripper is to
be installed.
►Switch 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.
7.2 Installation of the mechanical system
7.2.1 General installation information
NOTICE:
TheLEDringorplasticringandtheadapterangemustbeabsolutelyushwitheachotherbefore
pulling out the grub screws (“IO-Link”) or fastening screws (“digital + integrated analog sensing”).
Non-compliance may result in property damage.

INSTALLATION AND OPERATING INSTRUCTIONS: 2-jaw parallel gripper, electric, HRC-03 series
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Zimmer GmbH ●Im Salmenkopf 5 ●77866 Rheinau, Germany ●[phone] ● [phone] ●www.zimmer-group.com
DDOC00268 / gEN / 2020-01-10
7.2.2 “IO-Link” installation
Thegripperandtherobotareconnectedtoeachotherviaanadapterange.
Thegrippermustbeinstalledonamountingsurfaceinaccordancewiththelevelnessspecications.
Length < 100 mm permitted unevenness < 0.02 mm
Length>100mmpermitted unevenness < 0.05 mm
The following work steps must be observed during installation:
►Unscrew the four grub screws 8andwithdrawtheadapterange6from the gripper housing.
► Positiontheadapterange6ontherobotheadormediaangeusingthestraightpin2a.
► Mounttheadapterange6ontherobotheadormediaangeusingthemountingscrews2b.
ÖA suitable screw-in depth has to be chosen for the application.
ÖRecommended screw-in depth = at least 1.5xØ
ÖMounting screws are included in the scope of delivery.
ÖStrength class of the mounting screws at least 8.8 ÖDIN EN ISO 4762.
ÖObserve the tightening torque of the mounting screws.
ÖMakesurethemountingsurfaceissu󹱺cientlyrigidandlevel.
► Reinsertthegripperintheadapterange6. ÖWhile doing so, observe the positions of the
straight pin bl or the centering device 9and the LED ring 3.
►Screw the four grub screws 8into the drilled holes 7again and tighten.

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7.2.3 “IO-Link” installation with adapter plate
The gripper and the robot are connected to each other
via an adapter plate.
The gripper must be installed on a mounting surface in
accordancewiththelevelnessspecications.
Length < 100 mm permitted unevenness < 0.02 mm
Length>100mmpermitted unevenness < 0.05 mm
The following work steps must be observed during
installation:
►Position the adapter plate bn on the
robot using the straight pin 2a.
►Mount the adapter plate bn on the robot
using the mounting screws 2a.
►Unscrew the four grub screws 8and
withdrawtheadapterange6from the
gripper housing.
► Positiontheadapterange6on the
reducer for the adapter plate bm or media
angeusingthestraightpin2a.
► Mounttheadapterange6on the
adapter plate bmormediaangeusing
the mounting screws 2a.
►Position the adapter plate bm or media
angeontheadapterplatebn using the
straight pin 2a.
►Reinsert the gripper into the adapter
ange6.
►Screw in the four grub screws 8again
and tighten.
ÖTherobotangeadapterplatebn has a
pitch circle diameter (PCD) of 50 mm.
ÖA suitable screw-in depth has to
be chosen for the application.
ÖRecommended screw-in depth =
at least 1.5xØ
ÖMounting screws are included in the
scope of delivery.
ÖStrength class of the mounting
screws at least 8.8
ÖDIN EN ISO 4762.
ÖObserve the tightening torque of the
mounting screws.
ÖMake sure the mounting surface is
su󹱺cientlyrigidandlevel.

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DDOC00268 / gEN / 2020-01-10
7.2.4 “Digital + integrated analog sensing” installation
ÖThere is no LED ring for this gripper variant. A single-color plastic ring 3replaces the LED ring.
Thegripperandtherobotareconnectedtoeachotherviaanadapterange.
Thegrippermustbeinstalledonamountingsurfaceinaccordancewiththelevelnessspecications.
Length < 100 mm permitted unevenness < 0.02 mm
Length>100mmpermitted unevenness < 0.05 mm
The following work steps must be observed during installation:
►Unscrew the two fastening screws 8and withdraw the sleeve bm and the plastic ring 3.
►Position the straight pin 2ainto the drilled hole 2aoftheadapterange6that is required for
positioning.
ÖThere are four positioning options available.
►Screw two mounting screws 2binto the designated installation hole 2band install the adapter
ange6ontherobotheadormediaange.
ÖA suitable screw-in depth has to be chosen for the application.
ÖRecommended screw-in depth = at least 1.5xØ
ÖMounting screws are included in the scope of delivery.
ÖStrength class of the mounting screws at least 8.8 ÖDIN EN ISO 4762.
ÖObserve the tightening torque of the mounting screws.
ÖMakesurethemountingsurfaceissu󹱺cientlyrigidandlevel.
►Slide the sleeve bm and the plastic ring 3onthegripperandpositionontheadapterange6.
►Attach the sleeve bmontheadapterange6using the two fastening screws 8.

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7.2.5 “Digital” installation
The gripper and the robot are connected to each other
viaanadapterange.
The gripper must be installed on a mounting surface
inaccordancewiththelevelnessspecications.
Length < 100 mm permitted unevenness < 0.02 mm
Length>100mmpermitted unevenness < 0.05 mm
The following work steps must be observed during
installation:
►Unscrew the two fastening screws 8and withdraw
the sleeve bm and the plastic ring 3.
►Position the straight pin 2ainto the drilled hole
2aoftheadapterange6that is required for
positioning.
ÖThere are four positioning options
available.
►Screw two mounting screws 2binto the
designated installation hole 2band install the
adapterange6on the robot head or media
ange.
ÖA suitable screw-in depth has to
be chosen for the application.
ÖRecommended screw-in depth
= at least 1.5xØ
ÖMounting screws are included in the
scope of delivery.
ÖStrength class of the mounting screws
at least 8.8 ÖDIN EN ISO 4762.
ÖObserve the tightening torque of the
mounting screws.
ÖMake sure the mounting surface is
su󹱺cientlyrigidandlevel.
►Slide the sleeve bm and the plastic ring 3on the
gripperandpositionontheadapterange6.
►Attach the sleeve bmontheadapterange6using the two fastening screws 8.
INFORMATION:
ÖThere is no LED ring for this gripper variant. A single-color plastic ring 3replaces the LED ring.
ÖThis gripper variant features a cutout cl in the sleeve bmforadjustingthemagneticeldsensors.
➔This only applies to the gripper with a digital sensor.
➔Grippers for which analog sensors are used do not require this cutout.

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DDOC00268 / gEN / 2020-01-10
7.3 Installation of the electrical system
7.3.1 Installation of the wiring
• Connect the supply cable to the gripper and the control system.
► Youcanndthecorrespondingsupplycableonour
website
►www.zimmer-group.com
INFORMATION:
The cables that are used by Zimmer GmbH feature a minimum bending radius of 10 x the outer
diameter.
This bending radius must not be undershot!
►All IO-Link cables that are installed in grippers have an outer diameter of 5 mm and thus a bending
radius of 50 mm.
►Freely suspended cables must be secured to prevent excessive motion loads or pinching.
7.3.2 “Digital” and “Digital + integrated analog sensing”
INFORMATION:
For information on the “Digital” and “Digital + integrated analog sensing” grippers, refer to the “robot-
specic”installationandoperatinginstructions(DDOC00268-01).
These“robot-specic”installationandoperatinginstructionsareincludedwiththegripperaswelland
can be found on our website.
Zimmer Customer Service is available to provide you assistance if you have any further questions.

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7.3.3 “IO-Link” installation
HRC-03-072840
HRC-03-072844
PIN assignment of the power supply line:
PIN Color Function Explanation
1Brown Sensor + 24 V DC Power supply for IO-Link communication
2White Actuator + 24 V
DC Actuator supply voltage
3Blue GND sensor Sensor 0 V DC supply voltage
4Black C/Q IO-Link communication
5Gray GND actuator Actuator 0 V DC supply voltage
The following steps must be carried out for commissioning or installation of the gripper with IO-Link:
• Connect the gripper to the IO-Link master.
• Ensure the voltage supply.
►For Port Class A, additional power supply via Y-cable.
7.4 Static charge
The movement of the gripper jaws create low voltages as a result of static charging. These charges cannot
be dissipated if the gripper is installed on an insulated surface and discharge is also not possible through the
workpiece.
NOTICE:
Non-compliance may result in property damage
Grounding the gripper attachment / gripper jaws is recommended if ESD-sensitive parts come into
contact with the gripper.
7.5 Heat dissipation
In the event of high ambient temperatures, the gripper has to be installed on heat-dissipating materials.
If the gripper is permanently operated under very high ambient temperatures and with fast cycle times, the service
life may be reduced.
7.6 Installation of 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 assistance if you have any further questions.

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8. Commissioning
8.1 “Analog” and “Digital” commissioning
8.1.1 Restart “Analog“ and “Digital“
INFORMATION:
When restarting the gripper, no signal must be present at PINS “DIR1” and “DIR2”.
Condition for a cold start:
„DIR1“ and „DIR2“ = 0 V
As soon as the green LED on the gripper lights up, it is ready for operation.
The gripper can be moved within a few ms of the power supply.
8.1.2 “Analog” and “Digital” switching sequence
A movement in the desired direction executes a high level of the corresponding signal.
After a high level is detected, the gripper always executes the gripper movement all the way to the end of the
gripping process.
It is important to ensure that, after a gripper movement has taken place, the corresponding signal is reset again
before a signal in the opposite direction is given.
Between withdrawing the signal and the next command, a pause of 10 ms must be observed.
NOTICE:
In order to prevent damage to the gripper, the resistance between the analog output and GND must
beatleast10kΩ.
INFORMATION:
ÖThemovementproleappliestothedigitalgripperaswellastothedigitalgripperwithanalog
sensing.
The current jaw position is scaled from 0 V to 10 V and is issued via pin 5 (analog output).
BasePosition
WorkPosition
► ◄ ≥ 10 ms ► ◄ ≥ 10 ms ► ◄ ≥ 10 ms
0
1
0
1
Signal „öffnen“
Signal „schließen“
BasePosition
WorkPosition
BasePosition BasePosition
"Open" signal
"Close" signal WorkPosition WorkPosition
≥10ms ≥10ms ≥10ms

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8.2 IO-Link commissioning
8.2.1 Process data
The option exists for the gripper to be controlled only by the process data transmitted in each cycle.
Outputs: Process data from the IO-Link master to the gripper!
Name Data type
ControlWord UINT 16
DeviceMode UINT 8
Workpiece No. UINT 8
TeachPosition UINT 16
GripForce UINT 8
PositionTolerance UINT 8
Name Data type
Status UINT 16
Diagnosis UINT 16
ActualPosition UINT 16
Grippers
Input
Control
system
Edition

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DDOC00268 / gEN / 2020-01-10
8.2.2 IODD import
►Importing the IODD (device description) into the control system.
ÖCall up our website at Öwww.zimmer-group.com
ÖSelectthedesiredgripperanddownloadthecorresponding.zipleviathe“DownloadIODD”link.
ÖThe“.ziple”isrequiredforimportingintothecontrolsystem.
WhenthehardwarecongurationiscompleteandtheIO-Linkconnectiontothegripperisestablished,some
data must be visible in the process input data.
ÖSome control systems demand a byte swap to bring this process data into a logical sequence.
►To determine whether a byte swap is necessary, you can view bit 6 (GripperPLCActive) in the “StatusWord”.
► Forthispurpose,itisnecessarytodeterminewhetherbit6isactiveintherstorsecondstatusbyte.
ÖIfbit6isactiveintherstbyte,thebytesalreadyhavethecorrectsequenceandcommissioning
can be continued.
ÖIf bit 6 is active in the second byte, a byte swap still has to be applied here.
ÖFor further information, refer to the “StatusWord” section.
INFORMATION:
It is mandatory to verify the process data.
The control of the gripper takes place via IO-Link by means of the cyclical process data as well as the acyclical
service data with a cycle time of 5 ms.
8.3 “Handshake” data transfer method
All process data that is transferred to the gripper and is described in the sections that follow must be transferred
using the “handshake” method.
INFORMATION:
This method is referred to as a “handshake” because it enables “clean” transfer.
The process data transfer takes place, so to speak, from “hand to hand” - from the control system to
the gripper.
The following steps are required for the “handshake”:
The data transfer starts with the transfer of "ControlWord" = 0x01 to the gripper.
Subsequently, the response of the gripper must be tested by means of "Statusbit" 12 = TRUE (data trans-
fer OK).
Following this, the “ControlWord” = 0 can be sent, which ends the data transfer.
The operator automatically concludes the data transfer with the “ControlWord” = 0x00 and the corre-
sponding response from the gripper via the “Statusbit” 12 = FALSE .

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8.4 Parameter
8.4.1 “ControlWord” parameter
NOTICE:
In the “ControlWord” parameter, only one single bit or the value 0 may be set at a time. Only the
values listed in the following table are valid:
Parameter Decimal value Hexadecimal value
Data transfer 1 0 x 1
WritePDU 2 0 x 2
Teach 8 0 x 8
Adjust 128 0 x 80
MoveToBase 256 0 x 100
MoveToWork 512 0 x 200
ErrorReset 32768 0x8000
Name "ControlWord"
Data format UINT16
Permission Write
Transfer Cyclical
Value range 0 to 65535
“ControlWord” structure:
Bit 15 Bit 14 Bit 13 Bit 12 Bit 11 Bit 10 Bit 9 Bit 8
Byte 1 “Error
Reset” - - - - - "MoveToWork" "MoveToBase"
Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0
Byte 2 "Adjust" - - - "Teach" "ResetDirection-
Flag" "WritePDU" "Datatransfer"
Bit 0: „Datatransfer“
►Setting this bit causes the gripper to accept the data transmitted in the process data
(“WorkpieceNo” = 0) or the data stored in the workpiece data records (“WorkpieceNo = 1 to 32)
as the active data set.
Bit 1: „WritePDU“
►Setting this bit communicates to the gripper that it should write the current process data to the
selected tool recipe.
Bit 2: „ResetDirectionFlag“
► Settingthisbitinformsthegripperthatthedirectionagneedstobereset.
►This makes a repeated movement to a position possible.
►This is logical during a switchover of workpiece recipes.
Bit 3: „Teach“
►Setting this bit informs the gripper to save the current position as the “TeachPosition” in the
selected “WorkpieceNo”.
INFORMATION:
This only works if there is no “0” that is transmitted in the workpiece number!