Zimmer startZ User manual

www.zimmer-group.de
INSTALLATION AND
OPERATING
INSTRUCTIONS
startZ
Universal Robot
DDOC01095
THE KNOW-HOW FACTORY

INSTALLATION AND OPERATING INSTRUCTIONS: startZ Universal Robots
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
2
EN / 2020-11-30DDOC01095 / 0
Contents
1 Supporting documents......................................................................................................................................................... 4
1.1 Hazard levels of warning notices ...............................................................................................................................................................................4
2 Safety notices ........................................................................................................................................................................ 5
3 Proper use ............................................................................................................................................................................. 5
4 Personnelqualication ......................................................................................................................................................... 6
5 Product description .............................................................................................................................................................. 6
6 Function ................................................................................................................................................................................. 7
6.1 ComfortAppontherobotcontrolpanel ...................................................................................................................................................................7
6.2 Technicaldata..............................................................................................................................................................................................................7
7 Installation.............................................................................................................................................................................. 8
7.1 Installingthehardwarecomponents .........................................................................................................................................................................8
7.2 General installation information .................................................................................................................................................................................9
7.3 Installingthemechanicalsystem .............................................................................................................................................................................10
7.3.1 Installing GEH6000IL ..................................................................................................................................................................................10
7.3.2 Installing HRC-02.........................................................................................................................................................................................11
7.4 Installingthepowersupply.......................................................................................................................................................................................12
7.4.1 SCM pin assignment...................................................................................................................................................................................12
7.4.2 Installingthestandardwiring .....................................................................................................................................................................13
7.4.3 InstallingtheSCM .......................................................................................................................................................................................13
7.4.4 Pinassignmentoftherobotcontroller ......................................................................................................................................................14
7.5 HMI/URCaps software download ............................................................................................................................................................................15
7.6 SettinguptheEthernetconnection .........................................................................................................................................................................15
7.7 ConguringtheIO-LinkgripperwiththeSCM........................................................................................................................................................16
8 CommissioningtheSCM.................................................................................................................................................... 17
8.1 ConnectingwiththeSCM.........................................................................................................................................................................................17
8.2 SelectingthegripperinguideZmode.....................................................................................................................................................................18
8.3 Switchingonthemotorandreferencing .................................................................................................................................................................19
8.4 Selectingthedesiredgrippingdirection .................................................................................................................................................................20
8.5 Teaching-intheworkpiece........................................................................................................................................................................................21
8.6 Settingtheworkpiecetolerance ..............................................................................................................................................................................22
8.7 Settingtheopenposition..........................................................................................................................................................................................23
8.8 Settingthegrippingforce .........................................................................................................................................................................................24
8.9 Settingthespeedforopeningthegripper ..............................................................................................................................................................25
8.10 Checkingthesettings ...............................................................................................................................................................................................26
8.11 Savingtherecipe.......................................................................................................................................................................................................27
8.12 Endofsavingthedata ..............................................................................................................................................................................................28
8.13 monitorZmode..........................................................................................................................................................................................................29
8.14 expertZmode ............................................................................................................................................................................................................30
8.15 TestingthegripperwithSCM...................................................................................................................................................................................31
9 CommissioningtheSCM/HMIsoftware............................................................................................................................ 32
9.1 Switchingontherobot..............................................................................................................................................................................................32
9.2 ZimmerComfortURCap/USBstick.........................................................................................................................................................................33
9.3 Newgripperconguration........................................................................................................................................................................................36
9.3.1 Selectingtheconnection............................................................................................................................................................................36
9.3.2 ControllerI/O:Numberofgrippers ...........................................................................................................................................................36
9.3.3 ControllerI/O:Gripperseries ....................................................................................................................................................................37
9.3.4 ControllerI/O:Commandconnections.....................................................................................................................................................37
9.3.5 ControllerI/O:Statusconnections............................................................................................................................................................38
9.3.6 ControllerI/O:Manualcontrol ...................................................................................................................................................................40
9.3.7 ControllerI/O:Savingthegripperconguration......................................................................................................................................42

INSTALLATION AND OPERATING INSTRUCTIONS: startZ Universal Robots
3
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
EN / 2020-11-30DDOC01095 / 0
9.3.8 ControllerI/O:Adjustingtheconnectionassignment .............................................................................................................................42
9.4 RobotcoldstartaftersuccessfulZimmerinstallation............................................................................................................................................47
10 Operation.............................................................................................................................................................................49
10.1 Zimmergrippercontrolprinciple .............................................................................................................................................................................49
10.2 Overviewofgeneratedrobotcommands................................................................................................................................................................50
10.3 Exampleoftheuseofgeneratedrobotjobs...........................................................................................................................................................52
11 Troubleshooting .................................................................................................................................................................. 52
12 Accessories/scopeofdelivery........................................................................................................................................... 52
13 Decommissioning/disposal ............................................................................................................................................... 52

INSTALLATION AND OPERATING INSTRUCTIONS: startZ Universal Robots
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
4
EN / 2020-11-30DDOC01095 / 0
1 Supporting documents
NOTICE
Readthroughtheinstallationandoperatinginstructionsbefore installingtheproduct.
Theinstallationandoperatinginstructionscontainimportantnotesforyourpersonalsafety.Theymustberead
andunderstoodbyallpersonswhoworkwithorhandletheproductduringanyphaseoftheproductlifetime.
Thedocumentslistedbelowareavailablefordownloadonourwebsitewww.zimmer-group.com:
• Detailed 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.
1.1 Hazard levels of warning notices
DANGER
Thisnoticewarnsofanimminentdangertothelifeandhealthofpeople.Ignoringthesenoticescanleadto
seriousinjuryorevendeath!
►Youabsolutelymustcomplywiththedescribedmeasuresforavoidingthesedangers!
• Thewarningsymbolsareassignedaccordingtothetypeofdanger.
WARNING
Thisnoticewarnsofasituationthatispotentiallyhazardoustopersonalhealth.Ignoringthesenoticescancause
seriousinjuryordamagetohealth.
►Youabsolutelymustcomplywiththedescribedmeasuresforavoidingthesedangers!
• Thewarningsymbolsareassignedaccordingtothetypeofdanger.
CAUTION
Thisnoticewarnsofasituationthatispotentiallyhazardousforpeopleorthatmayresultinmaterialorenviron-
mentaldamage.Ignoringthesenoticesmayresultinslight,temporaryinjuriesordamagetotheproductortothe
environment.
►Youabsolutelymustcomplywiththedescribedmeasuresforavoidingthesedangers!
• Thewarningsymbolsareassignedaccordingtothetypeofdanger.
NOTICE
Generalnoticescontainusagetipsandvaluableinformation,butnowarningsofdangerstohealth.
INFORMATION
Thiscategorycontainsusefultipsforhandlingtheproducte󹱺ciently.Failuretoobservethesetipswillnotresult
indamagetotheproduct.Thisinformationdoesnotincludeanyinformationrelevanttohealthandworkplace
safety.

INSTALLATION AND OPERATING INSTRUCTIONS: startZ Universal Robots
5
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
EN / 2020-11-30DDOC01095 / 0
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mountedonindustrialmachines.
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itsintendeduseandtechnicaldata.ZimmerGmbHshall
acceptnoliabilityforanydamagecausedbyimproperuse.
AnyuseotherthantheintendeduserequireswrittenapprovalfromZimmerGmbH.
Makesurethatthepowersupplyisdisconnectedbeforeyouinstall,retoolorservicetheproduct.
ZimmerGmbHrecommendsperformingmaintenancetasks,renovationworkorattachmentworkoutsideofthe
machine'sdangerzonewhenpossible.
►Whencommissioningortesting,makesurethattheproductcannotbeactuatedbymistake.
►Modicationstotheproduct,suchasaddingdrilledholesorthreads,maybemadeonlywithpriorapproval
fromZimmerGmbH.
►Thespeciedmaintenanceintervalsaretobeobserved;alsorefertothe"Maintenance"section.Whenthe
productisusedunderextremeconditions,themaintenanceintervalmustbeadapted.
►Useoftheproductunderextremeconditions,suchasaggressiveliquidsandabrasivedusts,issubjectto
priorapprovalfromZimmerGmbH.
►Donotreachintotheoperationalrangeoftheproduct!
3 Proper use
NOTICE
Theproductisonlytobeusedinitsoriginalstatewithitsoriginalaccessories,withnounauthorizedchangesand
withinthestipulatedparameterlimitsandoperatingconditions.Anyotherorsecondaryuseisdeemedimproper.
Operatetheproductonlyincompliancewiththeassociatedinstallationandoperatinginstructions.
Operatetheproductonlywhenitisinatechnicalconditionthatcorrespondstotheguaranteedparametersand
operating conditions.
ZimmerGmbHshallacceptnoliabilityforanydamagecausedbyimproperuse.Theoperatorbearssolerespon-
sibility.
TheZimmerstartZboxbasicallyincludesaZimmergripper,theSCMnecessaryforactuationandtheappropriateUR
softwareaswellastheaccessoriesandconnectionmaterial.
TheSmartCommunicationModule(SCM)istheintelligentgatewaybetweentheIO-Linkgrippersandthedigitalrobot
inputsandoutputs.Itmayonlybeusedintheoriginalconditionwithitsoriginalaccessories,withoutunauthorizedchanges
andwithitsdenedparametersforuse.
Useoutsideofthedenedparametersisnotpermitted.Unauthorizedelectricalormechanicalmodicationsmustnotbe
made.
TheSCMisintendedexclusivelyforelectricoperationusinga24VDCpowersupply.
TheZimmerComfortURCapisusedwiththePolyscopebyUniversalRobotstodirectlycontrolZimmergrippers.Control
meansthemanualandembeddeduseofthegripperinthenormalrobotsequence.
Directcontactwithperishablegoods/foodisnotpermitted.

INSTALLATION AND OPERATING INSTRUCTIONS: startZ Universal Robots
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
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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.
Forunderstandingtheseinstallationandoperatinginstructions,itisimportanttobefamiliarwithandunderstandthe
manualsfromUniversalRobotsaswellastheinstallationandoperatinginstructionsoftheZimmergrippersused.
Moreinformationaboutthegripperingreaterdetailcanbefoundintheassociatedinstallationandoperatinginstructions.
5 Product description
Inprinciple,withthetwoproductsSCMandtheZimmerComfortApp,startZfromZimmerenablestheuseofamaximum
oftwoZimmerIO-Linkgrippers.
ThesegrippersmustbeinstalledonthetoolangeoftherobotandconnectedtotheSCM.
Asarule,thefollowingproductsfromZimmerGmbHcancurrentlybeoperated.Ifnecessary,thesuppliedgrippercan
thereforebereplacedwiththeproductsbelowatanytimetosuittheapplication,withoutsignicantlychangingtheuse.
BasicIO-Linkgripper AdvancedIO-Linkgripper
GEP2xxxIL GEH6xxxIL
GEP5xxxIL GED6xxxIL
GED5xxxIL HRC-01
GPP5xxxIL HRC-02
GPD5xxxIL
HRC-03
HRC-04
HRC-05
TheZimmerComfortAppcaninteractivelycallupanumberofrobotjobs,dependingonthecongurationandconnection
used.
Ifonlyonegripperisusedbytherobot,asecondgripperdoesnothavetobecongured.
ForthecontroloftheIO-LinkgripperfromtherobotcontrolviaZimmerComfortAppitisnecessarytousetheSCM.
TheSCMisavailableatZimmerGmbHandpartofthestartZbox.ItisanelectronicmoduleforthetranslationofIO-Link
signalsintosimple,digitalinputsandoutputs,inwhichprocessintheSCMthebehaviorofthegripperistrained.

INSTALLATION AND OPERATING INSTRUCTIONS: startZ Universal Robots
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Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
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6 Function
Theimagebelowshowstheschematicstructureoftheoverallsystem.AllnecessarypartsforthisareincludedinthestartZ
boxandcanbeobtainedasneededalsoindividuallyorinadifferentcombinationatZimmerGmbH.
Thefollowingoverviewpresentstheoverallsystemstructure:
expertZ guideZ monitorZ
1 2 3 4 5 6 7 ><
–R
X
B
Y
T
Z
–
–
+
+
+
R
X
B
Y
T
Z
E
M
E
R
G
E
N
C
Y
S
T
O
P
4 5
9
6
1 2 3
87
IsClosed
Reset MotorOn WP_00
< >
WP_01 WP_02
Error
Act_WP_00
IsReleased
Grip Release
Gripper 1: Manual control
IsGripped OnUndefinedPos
MotorOn
Act_WP_01
IO-Link connection cable
5 m M12 connecting cable 5x0.34
(max. cable length 10 m)
IO-Link - digital I/O
Zimmer Group SCM
Comfort App
24 V voltage supply
Temporary
Ethernet connection
Digital I/O
Robot control system
INFORMATION
BeforeactuationoftheIO-LinkgripperbytheSCM,thegrippingapplicationmustbetrainedintheSCM.Forthis
purpose,downloadtheZG_IO_LINK_HMIsoftwareandinstallonaWindowsPC.
6.1 Comfort App on the robot control panel
TheComfortApp,coordinatedtotherobotmanufacturer,makesitpossibletoactuateandoperatethegripperconveniently
anddirectlyusingtherespectiverobotcontrolpanel.Setupmodeandallnecessarycommandsforhitch-freeautomatic
mode.
6.2 Technical data
INFORMATION
Technicaldatacanbefoundonourwebsitewww.zimmer-group.com.
PleasecontactZimmerCustomerServiceifyouhaveanyquestions.

INSTALLATION AND OPERATING INSTRUCTIONS: startZ Universal Robots
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
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EN / 2020-11-30DDOC01095 / 0
7 Installation
7.1 Installing the hardware components
Exampledepictionofaninstalledgripperwithadapterplate,cableandVelcrotape:
Extension cable
M12, 5-pin
KAG500IL

INSTALLATION AND OPERATING INSTRUCTIONS: startZ Universal Robots
9
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
EN / 2020-11-30DDOC01095 / 0
7.2 General installation information
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.
CAUTION
Riskofinjuryintheeventofunexpectedmovementofthegripperwhenthepowersupplyisconnected.
►Switchoffthepowersupplytothegripperbeforeallwork.
►Securethepowersupplyagainstbeingswitchedonunintentionally.
►Checkthepowersupplyforanyresidualenergy.
NOTICE
Switchoffthepowersupplybeforeanyassembly,installationormaintenancework.
Thegrippermustbeinstalledonamountingsurfaceinaccordancewiththespecicationsforatness.
ÖPermissibleunevenness:0.03mm
• Mountingscrewsareincludedinthescopeofdelivery.
• Strengthclassofthemountingscrews≥8.8(DINENISO4762)
• Observethetighteningtorqueofthemountingscrews.
• Theexactinstallationpositionscanbefoundonthetechnicaldatasheetonourwebsite.

INSTALLATION AND OPERATING INSTRUCTIONS: startZ Universal Robots
Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] • [phone] •www.zimmer-group.com
10
EN / 2020-11-30DDOC01095 / 0
7.3 Installing the mechanical system
7.3.1 Installing GEH6000IL
Examplerepresentationofthegripperinstallation:
Thegripperismountedtotherobotusingthe
baseandadapterplate.
Ö10.25Nm(4xM6mountingscrews4/
adapter plate 2)
Ö3.0Nm(2xM4gripper/adapterplate2)
Ö3.0Nm(1xM4grippernger)
Thefollowingworkstepsmustbeobserved
duringinstallation:
►Positiontheadapterplate2onthe
gripper1.
ÖThealignmentiscarriedoutusingthe
centering pin 3.
►A󹱺xtheadapterplate2ontherobotusing
themountingscrews4.
►Positionthegripper5ontheadapterplate
2.
ÖThealignmentiscarriedoutusingthetwo
centering pins 6.
►Fixthegripper5withthemountingscrews
7totheadapterplate2.
Thereistheoptionofmountingthegripper
ngersintwopositions.
Thismeansthatthegrippercanbeusedfor
inside and outside gripping.
ÖThegripperngersmustalwaysbemounted
mirroringeachother.
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