Zimmer FWR Series User manual

INSTALLATION AND
OPERATING
INSTRUCTIONS
Tool changer
FWR series
DDOC01406
THE KNOW-HOW FACTORY
www.zimmer-group.com


3
1 Supporting documents ............................................................................................................................................................... 4
1.1 Notices and graphics in the installation and operating instructions ...............................................................................................................................4
2 Safety notices............................................................................................................................................................................... 5
3 Proper use .................................................................................................................................................................................... 6
4 Personnelqualication................................................................................................................................................................ 6
5 Product description ..................................................................................................................................................................... 7
5.1 Type plate .............................................................................................................................................................................................................................8
5.2 Product variants and compatibility.....................................................................................................................................................................................8
6 Functional description ................................................................................................................................................................. 9
6.1 Functional safety................................................................................................................................................................................................................10
6.2 Control ................................................................................................................................................................................................................................10
6.3 Self-locking mechanism ....................................................................................................................................................................................................10
7 Technical data ............................................................................................................................................................................ 10
8 Accessories ................................................................................................................................................................................11
8.1 Sensors...............................................................................................................................................................................................................................11
9 Transportation/storage/preservation....................................................................................................................................... 11
10 Installation .................................................................................................................................................................................. 12
10.1 Installing the storage station .............................................................................................................................................................................................13
10.2 Installing the stationary part..............................................................................................................................................................................................13
10.3 Installing the loose part .....................................................................................................................................................................................................14
10.4 Installing the stationary part and loose part ....................................................................................................................................................................15
10.5 Installing the energy supply ..............................................................................................................................................................................................16
10.6 Installing accessories ........................................................................................................................................................................................................17
10.6.1 Installing the energy elements............................................................................................................................................................................17
10.6.2 Installing the sensors...........................................................................................................................................................................................18
11 Commissioning ..........................................................................................................................................................................19
11.1 Settingupthestoragestationforthersttime ...............................................................................................................................................................19
11.2 Setting the sensors............................................................................................................................................................................................................19
11.2.1 Setting the sensors in the storage station .........................................................................................................................................................19
12 Maintenance............................................................................................................................................................................... 20
13 Decommissioning/disposal ...................................................................................................................................................... 20
14 RoHS declaration....................................................................................................................................................................... 21
15 REACH declaration.................................................................................................................................................................... 21
16 Declaration of Incorporation ..................................................................................................................................................... 22
17 Declaration of Conformity ......................................................................................................................................................... 23
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com
Content

4
1 Supporting documents
NOTICE
Read through the installation and operating instructions before installing or working with the product.
The installation and operating instructions contain important notes for your personal safety. They must be read
and understood by all persons who work with or handle the product during any phase of the product lifetime.
The documents listed below are available for download on our website www.zimmer-group.com.
• Installation and operating instructions
• Catalogs, drawings, CAD data, performance data
• Information on accessories
• Technical data sheets
• General Terms and Conditions, including warranty information.
ÖOnly those documents currently available on the website are valid.
In these installation and operating instructions, "product" refers to the product designation on the title page!
1.1 Notices and graphics in the installation and operating instructions
DANGER
This notice warns of an imminent danger to the life and health of people. Ignoring these notices can lead to
serious injury or even death.
►You absolutely must comply with the described measures for avoiding these dangers!
ÖThe warning symbols are assigned according to the type of danger.
WARNING
This notice warns of a situation that is potentially hazardous to personal health. Ignoring these notices can cause
serious injury or damage to health.
►You absolutely must comply with the described measures for avoiding these dangers!
ÖThe warning symbols are assigned according to the type of danger.
CAUTION
This notice warns of a situation that is potentially hazardous for people or that may result in material or environ-
mental damage. Ignoring these notices may result in slight, temporary injuries or damage to the product or to the
environment.
►You absolutely must comply with the described measures for avoiding these dangers!
ÖThe warning symbols are assigned according to the type of danger.
NOTICE
General notices contain usage tips and valuable information, but no warnings of dangers to health.
INFORMATION
Thiscategorycontainsusefultipsforhandlingtheproducteciently.Failuretoobservethesetipswillnotresult
in damage to the product. This information does not include any information relevant to health or workplace
safety.
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com

5
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.
The product is state-of-the-art.
Itisttedtoindustrialmachinesandisusedtohold,transportandstoreworkpieces.
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'stechnicaldata.Anychangesoradditionstotheintendeduseoftheproduct,aswellasmodications
to the 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.
►Make sure that the power supply is disconnected before you mount, adjust, modify, maintain or repair the
product.
►Whenever work is carried out on the product, make sure that the product cannot be actuated by mistake.
►Perform maintenance tasks, renovation work or attachment work outside of the machine's danger zone when
possible.
►Do not reach into the operational range of the product.
►Observethespeciedmaintenanceintervalsandspecicationsregardingthequalityoftheoperatingmaterial.
►When using the product under extreme conditions, adjust the maintenance interval according to the degree of
contamination.
WARNING
Risk of injury caused by suspended loads
Improper handling of suspended loads can cause serious injury.
►Always keep an adequate safety distance from suspended loads.
►Never walk underneath a suspended load.
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com

6
3 Proper use
NOTICE
The product is only to be used in its original state with its original accessories, with no unauthorized changes and
within the stipulated parameter limits and operating conditions.
Any other or secondary use is deemed improper.
►Operate the product only in compliance with the associated installation and operating instructions.
►Operate the product only when it is in a technical condition that corresponds to the guaranteed parameters
and operating conditions.
ÖZimmer GmbH shall accept no liability for any damage caused by improper use. The operator bears sole
responsibility.
The product is intended for industrial use.
The product is designated for use in closed facilities.
Direct contact with perishable goods/food is not permitted.
Observance of the technical data and of the 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.
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com

7
5 Product description
The product is a safe quick-change system.
The basic and proven safety principles from DIN EN 13849-1 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:
1Stationary part (FWRXXF-00-A)
2Loose part (FWRXXL-00-A)
3Storage station (AFWR1-XX-A)
For the overall safety of the function, all three components must be taken into account (see "Functional Safety" section).
3
1
2
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com

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5.1 Type plate
A type plate is attached to the housing of the product. XXX
XX-XXXXXX
am
an
Thearticlenumberandtheconrmationnumberareshownonthetype
plate.
am Article number
an Conrmationnumber
5.2 Product variants and compatibility
INFORMATION
►Youcanndinformationonourwebsite.
►Please contact Zimmer Customer Service if you have any questions.
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com

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6 Functional description
Thestoragestationisadeviceinwhichacompletelyequippedloosepartcanbeheldreadyinadenedposition.
Several storage stations can be used to hold differently equipped loose parts for operation with a stationary part.
The stationary part is installed on a robot system. It is used to hold a loose part.
The loose part automatically locks with the stationary part during automatic extending out of the storage station and
unlocks during retraction.
As an alternative, the loose part can be manually locked with and released from the stationary part.
4
4Locking
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com

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6.1 Functional safety
For the overall safety of the function, all three components (stationary part, loose part and storage station) must be taken
into account.
The safety function that ensures secure locking between the stationary and loose part of the product is implemented via
two redundant action channels that consist of a mechanical locking and springs.
Technical supplementary safety measures (sensors) provide a high degree of diagnostic coverage. The product can thus be
classiedintocontrolcategory3inaccordancewithChapter6.2.6ofDINENISO13849-1.AccordingtoFigure5,
Chapter4.5.4ofthespeciedstandard,thePLdcanbeachievedwiththisproduct.
FaulteliminationinaccordancewithDINENISO13849-2,AnnexA,TableA2andA3forthehelicalcompressionsprings
used can be given.
6.2 Control
INFORMATION
►Youcanndtheinformationinthetechnicaldatasheetonourwebsite.
►Please contact Zimmer Customer Service if you have any questions.
6.3 Self-locking mechanism
INFORMATION
Theconnectionofthexedandlooseparttakesplaceviaamechanicalself-lockingmechanismwithoutan
external power supply. Therefore, in case of a power supply failure (e.g. an emergency stop), the loose part
remains locked in the stationary part.
►Please contact Zimmer Customer Service if you have any questions.
7 Technical data
INFORMATION
►Youcanndtheinformationinthetechnicaldatasheetonourwebsite.
Thisdatavarieswithintheseries,dependingonthespecicdesign.
►Please contact Zimmer Customer Service if you have any questions.
Forthemaximumtoolweight,refertothetighteningtorque/tighteningforcespeciedinthetechnicaldata,takinginto
account the distance to the center of gravity and the mating force of the energy elements.
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com

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8 Accessories
INFORMATION
If any accessories not sold or authorized by Zimmer GmbH are used, the function of the product cannot be
guaranteed.ZimmerGmbHaccessoriesarespecicallytailoredtotheindividualproducts.
►For optional accessories and those included in the scope of delivery, refer to our website.
8.1 Sensors
Example image of a combination consisting of
a stationary part, loose part and storage
station.
5
5
6
The sensors of the storage station check
whether the loose part is present in the storage
station and the locking is ensured.
The sensor of the stationary part checks
whether the loose part and stationary part are
connected.
5Sensor of storage station
6Sensor of stationary part
9 Transportation/storage/preservation
►Transport and storage of the product must be done only with the original packaging.
►If the product has already been installed on the superordinate machine unit, care must be taken during transport to
ensure that no unexpected movements can occur.
►Before commissioning the product and after transport, check all power and communication connections as well as
all mechanical connections.
►If the product is stored for an extended period, the following points are to be observed:
►Keep the storage location as dust-free and dry as possible.
►Avoidtemperatureuctuations/observeandadheretothetemperaturerange.
►Avoid wind/drafts/water condensation formation.
►Cover the product with a weatherproof, tear-resistant foil to prevent dust.
►Pack the product and do not expose it to direct sunlight during storage.
►Clean all components. There must be no soiling left on the components.
►Visually inspect all components.
►Remove all foreign substances.
►Properly remove potential corrosion spots.
►Close electrical connections using suitable covers.
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com

12
10 Installation
WARNING
Risk of injury due to uncontrolled movements
Risk of injury in case of unexpected movement of the machine or system into which the product is to be installed.
►Switch off the energy supply of the machine before any work.
►Secure the power supply against being switched on unintentionally.
►Check the machine for any residual energy that may be present.
NOTICE
►Installationmayonlybecarriedoutbyqualiedpersonnelinaccordancewiththeseinstallationandoperating
instructions.
►Switch off the power supply before any assembly, installation or maintenance work.
►Installtheproductonanappropriatemountingsurfaceinaccordancewiththeatnessspecications.
INFORMATION
Requirements for the mounting surface:
• Permissible unevenness: 0.03 mm
Further installation information:
• The mounting screws are not included in the scope of delivery.
• Strength class of the mounting screws is at least 8.8 (DIN EN ISO 4762)
►Observe the tightening torque of the mounting screws.
►Verify the permitted load capacity of the required screw connections in accordance with VDI 2230.
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com

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10.1 Installing the storage station
►Insertstraightpinsintothetsofthestoragestation.
►Position the storage station on the mounting piece.
►Fasten the storage station using the mounting screws.
8
7
7Mounting screw
8Straight pins
10.2 Installing the stationary part
►Insertthestraightpinintothedesignatedtonthestationarypart.
►Insert the stationary part into the robot arm by the connection.
►Position the stationary part on the robot.
►Loosely attach the mounting screws.
►Tighten the mounting screws crosswise.
bl
9
bm
9Straight pins
bl Connection
bm Mounting screw
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com

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10.3 Installing the loose part
The loose part can be installed from above and below.
bn
bo
►Insertthestraightpinintothedesignatedtontheloosepart.
►Position the loose part on the tool.
►Loosely attach the mounting screws.
►Tighten the mounting screws crosswise.
bn Mounting screw
bo Straight pins
bn
bo
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com

15
10.4 Installing the stationary part and loose part
Example image of a combination consisting of a stationary part, loose part and storage station.
Manual exchange:
The loose part can be installed on the stationary part and locked
manually.
In factory condition, a lock is screwed on to both sides. Only this way can
the lock be operated manually.
Automatic exchange:
If a manual exchange is prohibited, the screw of the lock must be
removed. The lock has no effect on the automatic change.
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com

16
10.5 Installing the energy supply
►Mountthepush-tttings.
bp
bp
bp Push-ttting
INFORMATION
►Youcanndtheinformationaboutconnectingthreadsonthetechnicaldatasheetonourwebsite.
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com

17
10.6 Installing accessories
NOTICE
Before installing an accessory, make sure it is suitable for use with the selected variant.
►Youcanndinformationonourwebsite.
►Please contact Zimmer Customer Service if you have any questions.
10.6.1 Installing the energy elements
►Remove the cover.
bq
br
bs
bs
br
bq
►Mounttheenergyelementwiththetting
screw.
bq Cover
br Energy element
bs Fitting screw
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com

18
10.6.2 Installing the sensors
10.6.2.1 Installing the sensor on the stationary part
The illustration shows an example of the installation of a sensor.
bu
6
bt
►Guide the cable through the opening in the cover.
►Fasten the sensor on the stationary part.
►Install the sensor on the stationary part with the countersunk screw.
6Sensor of stationary part
bt Countersunk screw
bu Cover
10.6.2.2 Installing the sensor on the storage station
►Screw the sensors into the storage station.
5
5Sensor of storage station
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com

19
11 Commissioning
11.1 Setting up the storage station for the rst time
►Unscrew the mounting screw of the end
stop.
►Rotate the end stop 90°.
►Reinstall the end stop with the mounting
screw.
►After commissioning, turn the end stop back
again.
cm
cl
cl Mounting screw
cm Limit stop
11.2 Setting the sensors
11.2.1 Setting the sensors in the storage
station
5
5
►Bring the markings on the locking elements
of the loose part to the position of the
markings of the storage station.
►Turn in the sensors until they emit a signal.
►Fasten the sensors at this position.
►Coat the sensors with sealing lacquer.
5Sensor of storage station
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com

20
12 Maintenance
CAUTION
Material damage resulting from blowing out with compressed air
Blowing out the product with compressed air can cause malfunctions and pose a risk of accidents.
►Never purge the product with compressed air.
CAUTION
Material damage caused by liquid and solvent-based cleaners
Liquid and solvent-based cleaning agents can cause malfunctions and pose a risk of accidents.
►Do not clean the product with any cleaning agents that are liquid or contain solvents.
Operation of the storage station is maintenance-free.
Maintenance-free operation of the tool changer is guaranteed for up to 200,000 change cycles .
The maintenance interval may be shortened under the following circumstances:
• Dirty environment
• Improperuseandusethatdoesnotcomplywiththepowerspecications.
• Ambient temperature is too high.
►Even though the product is maintenance-free as mentioned above, perform a regular visual inspection to check for any
corrosion, damage or contamination.
►Have maintenance work be performed by Zimmer Customer Service whenever possible.
ÖDismantling and reassembling the product without authorization may result in complications, as special installation
equipment is required in some cases. Zimmer GmbH accepts no liability for any resulting malfunctions or damage.
13 Decommissioning/disposal
INFORMATION
When the product reaches the end of its operational phase, it can be completely disassembled and disposed of.
►Disconnect the product completely from the power supply.
►Dispose of the components properly according to the material groups.
►Comply with the locally applicable environmental and disposal regulations.
INSTALLATION AND OPERATING INSTRUCTIONS:FWR
DDOC01406 / - EN / 2022-05-10
Zimmer GmbH • Im Salmenkopf 5 • 77866 Rheinau, Germany • +49 7844 9138 0 • www.zimmer-group.com
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