Zimmer LWR50F Series User manual

www.zimmer-group.com
INSTALLATION
AND OPERATING
INSTRUCTIONS
Fixed part
LWR50F series
DDOC01074
THE KNOW-HOW FACTORY

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
Contents
1 Supporting documents......................................................................................................................................................... 3
1.1 Notices and graphics in the installation and operating instructions.......................................................................................................................3
2 Safety notices ........................................................................................................................................................................ 4
3 Proper use ............................................................................................................................................................................. 5
4 Personnelqualication ......................................................................................................................................................... 5
5 Product description .............................................................................................................................................................. 6
5.1 Forces and torques .....................................................................................................................................................................................................7
5.2 Type plate.....................................................................................................................................................................................................................7
5.3 Product variants and compatibility ............................................................................................................................................................................7
6 Function ................................................................................................................................................................................. 8
6.1 LED display (optional).................................................................................................................................................................................................9
6.2 Connect LED................................................................................................................................................................................................................9
6.3 Sensors ......................................................................................................................................................................................................................10
6.4 Functional safety .......................................................................................................................................................................................................11
6.5 Electricalspecications ............................................................................................................................................................................................12
6.6 Protection class .........................................................................................................................................................................................................12
6.7 Technical data............................................................................................................................................................................................................12
7 Installation............................................................................................................................................................................ 13
7.1 General installation information ...............................................................................................................................................................................13
7.2 Installing the mechanical system .............................................................................................................................................................................14
7.3 Installing the power supply.......................................................................................................................................................................................15
7.4 Static charge..............................................................................................................................................................................................................21
7.5 Heat dissipation.........................................................................................................................................................................................................21
7.6 Installing accessories................................................................................................................................................................................................21
8 Operation............................................................................................................................................................................. 22
8.1 Freedrive operation (optional) ..................................................................................................................................................................................22
9 Maintenance........................................................................................................................................................................ 23
9.1 Safety note .................................................................................................................................................................................................................23
9.2 Maintenance ..............................................................................................................................................................................................................23
10 Accessories/scope of delivery........................................................................................................................................... 24
11 Transportation/storage/preservation ................................................................................................................................ 24
12 Decommissioning/disposal ............................................................................................................................................... 24
13 RoHS declaration................................................................................................................................................................ 25
14 REACH declaration ............................................................................................................................................................. 25
15 Declaration of Incorporation .............................................................................................................................................. 26
16 Declaration of Conformity .................................................................................................................................................. 27

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EN / 5/1/2021DDOC01074 / 0
INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
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 the product or have anything to do with the product during any
phase
of the product life cycle.
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
• GeneralTermsandConditionswithspecicationsforthewarrantyentitlement
ÖOnly the 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
The individual hazard levels, notices and warnings are marked with signal words.
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
Thiscategorycontainsusefultipsforhandlingtheproducteciently.Failuretoobservethesetipswillnotresult
in damage to the product. This information does not include any information relevant to health or workplace
safety.

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
2 Safety notices
CAUTION
Risk of injury and material damage in case of non-compliance
Installation,commissioning,maintenanceandrepairsmayonlybeperformedbyqualiedspecialistsin
accordance with these installation and operating instructions.
Theproductisstate-of-the-art.Itisttedtoindustrialmachinesandisusedtohold,transportandstore
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
technicaldata.Anychangesoradditionstotheintendeduseoftheproduct,aswellasmodicationstothe
product, such as those in the following examples, require the written permission of the manufacturer:
• Useoftheproductunderextremeconditions,suchasaggressiveuidsorabrasivedusts
• 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,maintenanceandrepairsmayonlybeperformedbyqualiedspecialistsin
accordance with these installation and operating instructions.
►Make sure that the power supply is disconnected before you mount, adjust, modify, maintain or repair the
product.
►When commissioning or testing, make sure that the product cannot be unintentionally activated.
►Do not reach into the operational range of the product.
►Always perform maintenance at the required intervals.
►When the product is used under extreme conditions, the maintenance interval must be adapted depending on
the extent of the contamination.
►Perform maintenance tasks, renovation work or attachment work outside of the machine's danger zone when
possible.
Notes and handling regulations for electrostatically sensitive components
Electrostatically sensitive components are individual components, integrated circuits or assemblies that can be
damagedbyelectrostaticeldsorelectrostaticdischarge.
►When handling electrostatic components, make sure that persons, the work area and packaging are all fully
grounded.
►Touchelectroniccomponentsonlyinappropriatelyidentiedareaswithconductiveooringandonlyif:
• You are grounded by means of special bracelets.
• You wear shoes that are suitable and approved for the discharge of electrostatic charges.
►Do not bring electronic assemblies into contact with plastics and parts of clothing that have plastic content.
►Store electronic assemblies on conductive underlays only.
►Do not install electronic assemblies in the vicinity of data back-up devices or monitors (monitor distance >
100mm).
►Perform measurements on electronic assemblies only if:
• The measuring instrument is grounded (e.g. via a ground conductor)
• Themeasuringheadismomentarilydischargedbeforemeasuringwithaoatingmeasuringinstrument.

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
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.
Theproductisdesignedspecicallyfor(cooperative/collaborative)useonrobotsystemsandincombinationwiththe
MATCH quick-change system.
Theproductisdesignedexclusivelyforelectricoperationusinga24VDCpowersupply.
The product must always be mounted on materials that dissipate heat.
The product is intended for industrial use.
The product is to be used as intended in enclosed rooms for handling and holding.
Direct contact with perishable goods or food is not permitted.
Observance of the technical data and of the notes on installation and operating instructions in these installation and
operating instructions are part of proper use.
4 Personnel qualication
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.

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
5 Product description
The new multifunctional end-of-arm platform of Zimmer Group is equipped with an extensive portfolio of functions and with
universal communication interfaces. MATCH is compatible with any lightweight construction robot in the market.
InstallationofMATCHisincrediblyeasy.Thesystemcanbemountedtotherobotangeandsetupconvenientlywithjusta
few manual adjustments.
Theproductisasafequick-changesystem(xedpart).ThebasicandprovensafetyprinciplesfromDINISOEN13849-1
can be complied with only if original parts from Zimmer GmbH are used.
The original parts from Zimmer GmbH required for the safety principles are:
1Fixed part (LWR50F-XX)
2Loose part with gripper (LWR50L-XX)
3Storage station (ALWR1-50-A) (sensors optional)
Fortheoverallsafetyofthefunction,allthreecomponents(xedpart,loosepartwithgripper,andstoragestation)mustbe
taken into account (see „Funktionale Sicherheit“ auf Seite 11).
1
2
3

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
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:
• LWR50F 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.
The part number am and the serial number an are shown on the type plate. XXX
XX-XXXXXX
am
an
5.3 Product variants and compatibility
INFORMATION
For information on the product variants and their compatibility for the following product, please refer to our
website at www.zimmer-group.com:
• LWR50F
Please contact Zimmer Customer Service if you have any questions.

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
6 Function
The product is installed on a robot system. It is used to hold a loose part with a corresponding gripper.
The loose part automatically locks with the product during automatic movement out of the storage station; as an alternative,
the loose part can be manually installed on the product.
Whenthexedandloosepartarejoined,theinternalspring-pincontactsforsignaltransmissionarecontacted.Then,the
Connect LED changes color from red to green and a Connect signal (depending on the variant) is passed to the higher-level
control system.
The product can be operated with a wide variety of loose parts and their grippers. The prerequisite for this is a compatible
loose part.
Duetothedifferentlysizedcenteringpinsandmarksonthelooseparts,thexedpartcannotbeinstalledbackwards.
For information on the compatible loose parts, please refer to our website at www.zimmer-group.com.
The product is equipped with a hot-plug function, which allows for the replacement of a loose part while electrically live.
The loose part is designed in such a way that incorrect insertion into the storage station is not possible.
1Voltagesupply,robot/xedpart
2Locking
3Positioning/connection
4Pneumatic connection
5Pneumatic feedthrough
6Spring pin contacts
7Positioning the loose part
8Connect-LED
Freedrive(robot-specic)
9LED ring (optional)
bl Strain relief (accessory)
bm Grounding
3
4
bm
bl
2
4
1
6
7
5
8
2
9

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
6.1 LED display (optional)
An LED ring is optionally available for the product.
ThecolorsoftheLEDringreectthestatusoftheIO-Linkdeviceintheloosepart.TheLEDringenablesa360°status
display.
LED state Function of the Zimmer IO-Link products Function of the Schmalz IO-Link products
None No supply voltage. No supply voltage.
Flashing No connection to the IO-Link device. No connection to the IO-Link device.
Continuous light An error is present. An error is present.
(White)ashing Unknown IO-Link device. Unknown IO-Link device.
Continuous light - A warning is present.
Continuous light Taught-in workpiece gripped. Workpiece vacuumed (vacuum > H2)
Continuous light Gripper in end position or no taught-in part
gripped. Neutral state (vacuum > H2)
6.2 Connect-LED
LED state Function of the Zimmer IO-Link products Function of the Schmalz IO-Link products
None No supply voltage. No supply voltage.
Continuous light No loose part coupled. No loose part coupled.
Continuous light One loose part coupled. One loose part coupled.

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
6.3 Sensors
Exampledepictionofacombinationconsistingofaxedpart,loosepartwithgripperandstoragestation.
Check up to two sensors in the storage position to see whether the loose part is present in the storage station.
Thenmovethexedpartontheloosepartfromabove.Thecenteringpinsofthelooseparthelpininsertion.
Therobot,alongwiththexedpartandloosepart,movestothefrontpositionofthestoragestation.
Thetwosensorsintheinspectionposition(testchannel)respondifthelockingsareextendedandmakecontactinthexed
part.
Whenthexedandloosepartarejoined,theinternalspring-pincontactsforsignaltransmissionarecontacted.Then,the
Connect LED changes color from red to green and a Connect signal (depending on the variant) is passed to the higher-level
control system.
bl Storage station bo Sensor for storage position (loose part present)
2Locking bp Sensor (locking extended) in inspection position (test
channel)
3Loose part for quick-change system bq Fixed part for quick-change system
2
bo
bp
bl
bq
2
3

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
6.3.1 Wiring diagram of the sensor system
Sensor plug connection M8 3-pin:
4
1 3
Circuit for sensor in storage position Circuit of two sensors in inspection position
+
-
1
3
4
Power Supply
Safety Input
+
-
1
3
4
Power Supply
Safety Input
+
-
1
3
4Safety Input
6.3.2 Setting the inspection position of the sensors
Bringtheloosepartlockedtothexedpartwithitsmarkingsonthelockingelementstothepositionofthefrontmarkings
bp of the storage station.
►Turn in the sensors bp until a signal is emitted.
►Fasten the sensors bp at this position.
►Coat the sensors bp with sealing lacquer (recommended).
6.3.3 Setting the storage position of the sensors
►Position a loose part in the storage station.
►Rotate the sensors bo in until the sensors emit a signal.
►Coat the sensors bo with sealing lacquer (recommended).
6.4 Functional safety
Fortheoverallsafetyofthefunction,allthreecomponents(xedpart,loosepartwithgripperandstoragestation)mustbe
taken into account.
Thesafetyfunction(securelockingbetweenthexedandloosepart)oftheproductisimplementedviatworedundant
action channels (mechanical locking/springs).
Technical supplementary safety measures (sensors) provide a high degree of diagnostic coverage. The product can thus be
classiedintocontrolcategory3inaccordancewithChapter6.2.6ofDINENISO13849-1.AccordingtoFigure5,Chapter
4.5.4ofthespeciedstandard,thePLdcanbeachievedwiththisproduct.
Fault elimination in accordance with DIN EN ISO 13849-2, Annex A, Table A2 and A3 for the helical compression springs
used can be given.

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
6.5 Electrical specications
INFORMATION
Forelectricalspecications,pleaserefertoourwebsiteatwww.zimmer-group.com.
Thisdatavarieswithintheseries,dependingonthespecicdesign.
Please contact Zimmer Customer Service if you have any questions.
6.6 Protection class
NOTICE
The product achieves protection class IP40 in all mounted positions of installation.
6.7 Technical data
INFORMATION
For technical data, refer to our website at www.zimmer-group.com.
Thisdatavarieswithintheseries,dependingonthespecicdesign.
Please contact Zimmer Customer Service if you have any questions.

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
7 Installation
7.1 General installation information
WARNING
Risk of injury due to uncontrolled movement
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 machine against being switched on unintentionally.
►Check the machine for any residual energy that may be present.
CAUTION
Risk of injury due to uncontrolled movement
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 product for any residual energy that may be present.
NOTICE
Switch off the power supply before any assembly, installation or maintenance work.
Theproductmustbeinstalledonasuitablemountingsurfaceinaccordancewiththeatnessspecications.
ÖPermissible unevenness: 0.03 mm
• The mounting screws are not included in the scope of delivery.
• Strengthclassofthemountingscrews:≥8.8(DINENISO4762)
• Observe the tightening torque of the mounting screws.
ÖZimmer GmbH recommends verifying the permitted load-carrying capacity of the required screw connections in
accordancewithVDI2230.
• The exact installation positions can be found on the technical data sheet on our website.

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
7.2 Installing the mechanical system
NOTICE
Non-compliance may result in material damage.
The following work steps must be observed
during installation:
►Insert the product into the robot arm by the
connection3.
►Loosely attach the mounting screws bm.
►Tighten the mounting screws bm crosswise. 3
bm

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
7.3 Installing the power supply
The following work steps must be observed during installation:
►Connect the product with the robot or route the connecting cable
along the robot to the IO-Link master.
CAUTION
Getting caught in the connecting cable when the robot is moving
Risk of injury due to entangled limbs or hair.
►Route the connecting cable as closely to the robot arm as possible.
►Avoid the danger zone.
NOTICE
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!
►Freely suspended cables must be secured to prevent excessive motion loads or pinching.
7.3.1 Installation of LWR50F-00-04-A and LWR50F-00-05-A
Activation is done via SCM or a commercially available IO-Link master with Port Class B.
Pin Color Function Explanation
3
21
45
M12, 5-pin
Connector/bracket
1Brown +24VDCsensor Power supply for IO-Link communication
2White +24VDC
actuator Actuator supply voltage
3Blue GND sensor 0Vsensorsupplyvoltage
4Black C/Q IO-Link communication
5Gray GND actuator 0Vactuatorsupplyvoltage

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
7.3.2 Installing LWR50F-01-03-A
Theselectedxedpartisequippedwithan
integrated Smart Communication Module
(SCM) with RS485 interface.
For installation and commissioning
???
???
...
Pin Color Function Explanation
6
12
48
3
5
7
M8, 8-pin
Socket/bracket
1White Signal RS485+
2Brown Signal RS485-
3Green Output 2 Connectsignal:24Vifloosepartis
coupled.
4Yellow Output 1 Freedrivesignal:24VifFreedrivebutton
is pressed.
5Gray +24VDC +24VDCsupplyvoltage
6Pink Input 1
7Blue Input 2
8Red GND 0Vsupplyvoltage

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
7.3.3 Installing LWR50F-08-01-A
Pin Color Function Explanation
4
21
68
7
5
3
M12, 8-pin
Connector/bracket
1White GND 0Vsupplyvoltage
2Brown +24VDC +24VDCsupplyvoltage
3Green Input 2
Informational messages, see installation
and operating instructions of the loose
part.
4Yellow Input 1
Informational messages, see installation
and operating instructions of the loose
part.
5- - -
6- - -
7Blue Output 2
Informational messages, see installation
and operating instructions of the loose
part.
8Red Output 1
Informational messages, see installation
and operating instructions of the loose
part.
TheinputsoftheproductareconguredforPNPoutputsofthecontrolsystem.

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
7.3.4 Installing LWR50F-10-01-A
Pin Color Function Explanation
4
21
68
7
5
3
M8, 8-pin
Connector/bracket
1White Output 1
Informational messages, see installation
and operating instructions of the loose
part.
2Brown Input 1
Informational messages, see installation
and operating instructions of the loose
part.
3Green Input 2
Informational messages, see installation
and operating instructions of the loose
part.
4Yellow n. c. -
5Gray +24VDC +24VDCsupplyvoltage
6Pink Output 3
Connectsignal24Vifloosepartis
coupled.
Informational messages, see installation
and operating instructions of the loose
part.
7Blue Output 2
Informational messages, see installation
and operating instructions of the loose
part.
8Red GND 0Vsupplyvoltage
TheinputsoftheproductareconguredforPNPoutputsofthecontrolsystem.

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
7.3.5 Installation of LWR50F-01-02-A and LWR50F-07-01-A
Pin Color Function Explanation
6
12
48
3
5
7
M8, 8-pin
Socket/bracket
1White Analog output 0to10VDCoutput
2Brown Output 3
Connectsignal24Vifloosepartis
coupled.
Informational messages, see installation
and operating instructions of the loose
part.
3Green Output 2
Informational messages, see installation
and operating instructions of the loose
part.
4Yellow Output 1 Output, control output for outward move
command.
5Gray +24VDC +24VDCsupplyvoltage
6Pink Input 1
Informational messages, see installation
and operating instructions of the loose
part.
7Blue Input 2
Informational messages, see installation
and operating instructions of the loose
part.
8Red GND 0Vsupplyvoltage
TheinputsoftheproductareconguredforNPNoutputsofthecontrolsystem.

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INSTALLATION AND OPERATING INSTRUCTIONS: Fixed part, LWR50F series
7.3.6 Installing LWR50F-09-01-A
Pin Color Function Explanation
6
12
48
3
5
7
M8, 8-pin
Socket/bracket
1White Analog output
Informational messages, see installation
and operating instructions of the loose
part.
2Brown Output 3
Connectsignal24Vifloosepartis
coupled.
Informational messages, see installation
and operating instructions of the loose
part.
3Green Output 2
Informational messages, see installation
and operating instructions of the loose
part.
4Yellow Output 1
Informational messages, see installation
and operating instructions of the loose
part.
5Gray +24VDC +24VDCsupplyvoltage
6Pink Input 1
Informational messages, see installation
and operating instructions of the loose
part.
7Blue Input 2
Informational messages, see installation
and operating instructions of the loose
part.
8Red GND 0Vsupplyvoltage
TheinputsoftheproductareconguredforPNPoutputsofthecontrolsystem.
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