Zimmer GEH8000 Series User manual

www.zimmer-group.com
INSTALLATION AND
OPERATING
INSTRUCTIONS
GEH8000 series
2-jaw parallel gripper
with long stroke
DDOC00262
THE KNOW-HOW FACTORY

Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] •www.zimmer-group.com
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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
Parameter explanation (glossary)
Parameter Explanation
ActualPosition Value of the current position of the product [1/100mm]
BasePosition Outer jaw position
Depending on the gripper prole, this can also be a work position.
ControlWord Activation of the product
Only one bit is permitted to be active in the word. The value "0" is also permitted.
DeviceMode Used to select gripping proles as well as the additional help modes in the product.
Diagnosis If an error occurs, outputs a diagnostic code that can be compared with the error list.
DIR Direction/24 V supply line
Depending on the product, this signal is used to move the product.
Error Error
GND Abbreviation for ground connection
GripForce Setting the gripping force
Offset Correction value
PositionTolerance Tolerance window for TeachPosition, BasePosition and WorkPosition
The value of the parameter acts in both directions.
ShiftPosition Toggle position between pre-positioning and the gripping process
StatusWord In its bits, returns the most important information about the status of the product to the control
system.
Teach/Adjust Program/Congure
Using this signal, depending on the gripper type, the current position of the product jaws can
be taught in as the new workpiece position.
Adjust is used to dene the reachable end positions of the product jaws.
TeachPosition Actual workpiece position
Travel routing Dened procedure for movement of the gripper jaws
Travel path Path on which the gripper jaws travel.
WorkpieceNo Selection of the workpiece recipes stored in the product
WorkPosition Inner jaw position at the product
Depending on the application, this can also be the standby position.

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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
Content
1 Supporting documents ......................................................................................................................................................... 5
1.1 Notices and graphics in the installation and operating instructions .......................................................................................................................5
2 Safety notices ........................................................................................................................................................................ 6
3 Proper use ............................................................................................................................................................................. 7
4 Personnel qualication ......................................................................................................................................................... 7
5 Product description .............................................................................................................................................................. 7
5.1 Type plate .....................................................................................................................................................................................................................7
6 Functional description .......................................................................................................................................................... 8
6.1 Position measuring system of the at swivel unit .....................................................................................................................................................8
6.1.1 Single-turn absolute encoder .......................................................................................................................................................................8
6.1.2 Multiturn absolute encoder ..........................................................................................................................................................................8
7 Technical data ....................................................................................................................................................................... 9
7.1 Forces and torques .....................................................................................................................................................................................................9
7.2 Protection class ...........................................................................................................................................................................................................9
8 Accessories/scope of delivery ............................................................................................................................................. 9
9 Transportation/storage/preservation .................................................................................................................................. 9
10 Installation ............................................................................................................................................................................10
10.1 Installing the product ................................................................................................................................................................................................11
10.2 Installing connection terminal X3 .............................................................................................................................................................................11
10.3 Installing the energy supply ......................................................................................................................................................................................12
10.3.1 Connecting the battery box ........................................................................................................................................................................12
10.4 Installing accessories ................................................................................................................................................................................................13
10.5 Checking operational readiness ..............................................................................................................................................................................13
11 Commissioning ................................................................................................................................................................... 14
11.1 Initial commissioning in Easy Startup mode ...........................................................................................................................................................14
11.1.1 Setting the IP address .................................................................................................................................................................................14
11.1.2 Setting the IP address .................................................................................................................................................................................15
11.1.3 Referencing the motor encoder of the GEH8660 .....................................................................................................................................25
11.2 EtherCat function block ............................................................................................................................................................................................28
11.2.1 IndraDrive Bosch Rexroth...........................................................................................................................................................................28
11.2.2 Conguring the IndraDrive converter ........................................................................................................................................................28
11.2.3 Installing the latest ESI Device Description ...............................................................................................................................................29
11.2.4 Establishing the connection to the IndraDrive controller .........................................................................................................................29
11.2.5 Establishing the IndraDrive Ds Ethernet connection to the IndraDrive Cs controller ............................................................................35
11.3 Conguring the interface from TwinCat3 ................................................................................................................................................................36
11.3.1 Checking the startup parameters ..............................................................................................................................................................36
11.3.2 Output parameters axis PLC .................................................................................................................................................................37
11.3.3 Input parameters PLC  axis ....................................................................................................................................................................38
11.3.4 Linking the interface with PLC ...................................................................................................................................................................41
11.4 Integrating blocks of the example ............................................................................................................................................................................43
11.5 Functions of the function block ................................................................................................................................................................................44
11.5.1 b_Power .......................................................................................................................................................................................................44
11.5.2 b_Automatic ................................................................................................................................................................................................44
11.5.3 b_TorqueMode ............................................................................................................................................................................................44
11.5.4 b_MoveToWorkPos .....................................................................................................................................................................................44
11.5.5 b_MoveToWorkPos_2 .................................................................................................................................................................................44
11.5.6 b_MoveToBasePos .....................................................................................................................................................................................44
11.5.7 b_SetReferencePos ....................................................................................................................................................................................44

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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
11.5.8 _Halt .............................................................................................................................................................................................................45
11.5.9 b_Fehler_Reset ...........................................................................................................................................................................................45
11.5.10 b_JogPlus ....................................................................................................................................................................................................45
11.5.11 b_JogMinus .................................................................................................................................................................................................45
11.5.12 i_Velocity ......................................................................................................................................................................................................45
11.5.13 i_AccDec ......................................................................................................................................................................................................45
11.5.14 i_Torque ......................................................................................................................................................................................................45
11.5.15 st_Parameter ...............................................................................................................................................................................................46
11.6 Input values for DES140/DES190 ............................................................................................................................................................................46
11.7 Function block TIA gantry ........................................................................................................................................................................................47
11.7.1 IndraDrive Bosch Rexroth...........................................................................................................................................................................47
11.7.2 Conguring the IndraDrive converter ........................................................................................................................................................47
11.7.3 Conguring the hardware ...........................................................................................................................................................................52
11.7.4 Integrating the library ..................................................................................................................................................................................54
11.7.5 MAIN ............................................................................................................................................................................................................55
11.7.6 PLC Variables ..............................................................................................................................................................................................56
11.7.7 Using the function block .............................................................................................................................................................................56
11.7.8 Functions of the function block .................................................................................................................................................................57
11.7.9 Input values for GEH8660S ........................................................................................................................................................................59
12 Gripping force charts ..........................................................................................................................................................59
13 Maintenance ........................................................................................................................................................................ 59
14 Decommissioning and disposal ......................................................................................................................................... 59
15 RoHS declaration ................................................................................................................................................................ 60
16 REACH declaration ............................................................................................................................................................. 60
17 Declaration of Incorporation .............................................................................................................................................. 61
18 Declaration of Conformity ..................................................................................................................................................62

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Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] •www.zimmer-group.com
EN / 2022-04-08DDOC00262 / c
INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
1 Supporting documents
NOTE
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 the documents currently available on the website are valid.
In these installation and operating instructions, "product" replaces 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
This category contains useful tips for handling the product e󹱺ciently. Failure to observe these tips will not result
in damage to the product. This information does not include any information relevant to health or workplace
safety.

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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
2 Safety notices
CAUTION
Risk of injury and material damage in case of non-compliance
Installation, commissioning, maintenance and repairs may only be performed by qualied specialists in
accordance with these installation and operating instructions.
The product is state-of-the-art.
It is tted to industrial machines and is used to hold, transport and store workpieces.
The following are examples of situations in which the product may cause a hazard:
• The product is not properly installed, used or maintained.
• The product is not used for its designated purpose.
• The locally applicable regulations, laws, directives or guidelines are not observed.
►The product may only be used in accordance with these installation and operating instructions and the
product's technical data. Any changes or additions to the intended use of the product, as well as modications
to the product, such as those in the following examples, require the written permission of the manufacturer:
• Use of the product under extreme conditions, such as aggressive uids or abrasive dusts
• Additional drilled holes or threads
ÖZimmer GmbH shall accept no liability for any damage caused by improper use. The operator bears sole
responsibility.
►Make sure that the power supply is disconnected before you mount, adjust, modify, maintain or repair the
product.
►Whenever work is carried out on the product, make sure that the product cannot be actuated by mistake.
►Perform maintenance tasks, retrotting or attachment work outside of the machine's danger zone when
possible.
►Do not reach into the operational range of the product.
►Observe the specied maintenance intervals and compressed air quality specications.
►When using the product under extreme conditions, adjust the maintenance interval according to the degree of
contamination.

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Zimmer GmbH •Im Salmenkopf 5 •77866 Rheinau, Germany •[phone] •www.zimmer-group.com
EN / 2022-04-08DDOC00262 / c
INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
3 Proper use
NOTICE
The product is only to be used in its original state with its original accessories, with no unauthorized changes and
within the stipulated parameter limits and operating conditions.
Any other or secondary use is deemed improper.
►Operate the product only in compliance with the associated installation and operating instructions.
►Operate the product only when it is in a technical condition that corresponds to the guaranteed parameters
and operating conditions.
ÖZimmer GmbH shall accept no liability for any damage caused by improper use. The operator bears sole
responsibility.
The product is designed exclusively for electric operation using a 110 - 230 V AC power supply.
The product is to be used as intended in enclosed rooms for temporary gripping, handling and holding.
The product 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 trained specialists. These persons must have read
and understood the installation and operating instructions in full.
5 Product description
5.1 Type plate
A type plate is attached to the housing of the product.
The type plate shows the part number and serial number. XXX
XX-XXXXXX
am
an
am Part number
an Serial number

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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
6 Functional description
The product has very high gripping force. This allows secure handling of even the heaviest workpieces.
The combination of servo drive (position, speed and force control) and mechanical self-locking mechanism ensures a high
degree of functionality.
The customer can individually equip the gripper jaws, which run parallel to one another. This ensures a high degree of
exibility.
1Power supply
2Removable centering sleeve
3Gripper jaw
4Linear guide
5Synchronization
6Drive
7Mounting and positioning
8Housing
2
13
4
5
6
7
8
6.1 Position measuring system of the at swivel unit
The drive of the product has a motor with single-turn absolute encoder with 17-bit resolution.
To use this absolute encoder as a 20-bit multiturn absolute encoder, we recommend using the battery box contained in the
scope of delivery of the converter.
6.1.1 Single-turn absolute encoder
INFORMATION
When this encoder variant is used, the absolute axis position is lost after the voltage is shut off.
The single-turn absolute encoder is used for absolute indirect position measurement within a motor revolution.
6.1.2 Multiturn absolute encoder
INFORMATION
When this encoder variant is used, the absolute axis position is maintained with the battery buffer even after the
voltage is shut off.
The multiturn absolute encoder is used for absolute indirect position measurement within 66536
motor revolutions.
If the motor is disconnected from the battery box, the information about the absolute axis position is lost after about one
minute. It replaces a separate absolute value at the motor.
Using the multiturn option requires buffer storage via an external battery. The following accessories must be used for this:
• Battery box SUP-E02-MSM-BATTERYBOX-xxx

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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
7 Technical data
INFORMATION
►You can nd the information in the technical data sheet on our website.
This data varies within the series, depending on the specic design.
►Please contact Zimmer Customer Service if you have any questions.
7.1 Forces and torques
INFORMATION
►You can nd the information in the technical data sheet on our website.
►Please contact Zimmer Customer Service if you have any questions.
7.2 Protection class
NOTICE
The product achieves protection class IP54 in all mounted positions of installation.
8 Accessories/scope of delivery
INFORMATION
If any accessories not sold or authorized by Zimmer GmbH are used, the function of the product cannot be
guaranteed. The accessories from Zimmer GmbH are specically tailored to the individual products.
►For information on optional accessories and those included in the scope of delivery, refer to our website.
9 Transportation/storage/preservation
►Transport and store the product only in the original packaging.
►During transport, make sure that no uncontrolled movements can occur if the product is already mounted on the
higher-level machine unit.
►Prior to commissioning and after transport, check all power and communication connections as well as all
mechanical connections.
►Observe the following points when storing the product for longer periods of time:
►Keep the storage location as dust-free and dry as possible.
►Observe the temperature range and avoid temperature uctuations.
►Avoid wind, drafts and formation of condensation.
►Cover the product with a weatherproof, tear-resistant foil to prevent dust.
►Avoid direct sunlight.
►Clean all components until all contamination on the components has been removed.
►Visually inspect all components.
►Remove any foreign objects.
►Remove potential corrosion spots properly.
►Seal electrical connections using suitable covers.

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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
10 Installation
WARNING
Risk of injury due to uncontrolled movement
Risk of injury in case of uncontrolled movements of the machine or system into which the product is to be
installed.
►Switch off the power supply of the machine before all work.
►Secure the power supply 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 uncontrolled 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.
CAUTION
Risk of injury due to objects being ejected
Spring-loaded components can jump out when installing or uninstalling the device.
NOTICE
►Installation may only be carried out by qualied personnel in accordance with these installation and operating
instructions.
►Switch off the power supply before any assembly, installation or maintenance work.
►Install the product on an appropriate mounting surface in accordance with the atness specications.
INFORMATION
Requirements for the mounting surface:
• Permissible unevenness: 0.03 mm
Further installation information:
• Strength class of the mounting screws is at least 8.8 (DIN EN ISO 4762)
►Comply with the tightening torques of the mounting screws.
►Verify the permitted load capacity of the required screw connections in accordance with VDI 2230.
►You can nd the exact installation positions in the technical data sheet on our website.

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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
10.1 Installing the product
The product can be installed from multiple sides.
The following illustration shows option 1.
Option 1:
►Insert the straight pin into the designated ts on the product.
►Use the straight pins to position the product on the provided
mounting piece.
►Push the mounting screws through the installation holes from the
opposite side.
►Fasten the mounting screws to the mounting piece.
9
bl
Option 2:
►Insert the straight pin into the designated ts on the product.
►Use the straight pin to position the product on the provided mounting
piece.
►Push the mounting screws through the customer-side installation
holes.
►Use the mounting screws to secure the product on the mounting
piece.
9Straight pin
bl Mounting screws
INFORMATION
►You can nd the information in the technical data sheet on our website.
This data varies within the series, depending on the specic design.
►Please contact Zimmer Customer Service if you have any questions.
10.2 Installing connection terminal X3
INFORMATION
►It is mandatory to comply with the illustrated clamping variants.
ÖZimmer GmbH shall accept no liability for any damage caused by improper use.
►For further information about the connection assignment for the BOSCH Rexroth HCS01 series servo
amplier, please refer to the manufacturer's planning instructions.
L1 L2 L3
3x110V
L1 L2 L3
3x230V
L1 N
1x230V L1 L2 L3
3x380V

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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
10.3 Installing the energy supply
►Connect downstream cables for connection
to a servo amplier to the product using
screw couplings.
• Motor cable
• Rotary encoder cable
►When routing the cables, make sure that
these do not run in the movement range of
the product.
►Maintain the permitted bending radii
specied by the manufacturer.
bq
br
bs
bq Servo amplier
br Motor cable
bs Rotary encoder cable
10.3.1 Connecting the battery box
INFORMATION
The delivery of the battery box includes a battery.
The battery box is delivered ready to operate.
The battery box "SUP-E02-MSM-BATTERYBOX" is an accessory set for operating MSM motors with absolute encoder (M5)
and is used for buffering encoder data when the voltage is shut off.
INFORMATION
If you replace the battery while the control voltage is shut off, the absolute encoder position and thus the position
reference of the axis is lost.
Type PRM1-03V6-2600C-D2-LITH-ZNR-50
Voltage 3.6V
Output 2600 mAh
Service life Up to 10 years, depending on the load and ambient temperature
Spare battery R911369925 (SUP-E02-MSM-BATTERY)

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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
10.4 Installing accessories
NOTICE
►Before installing the accessories, check whether they are suitable for use with the selected variant.
►Please contact Zimmer Customer Service if you have any questions.
10.5 Checking operational readiness
After the product has been properly installed, the following properties must be checked to verify that it is ready to be
operated:
►Check the energy supply.
►Check all mounting screws for their prescribed tightening torque.

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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
11 Commissioning
11.1 Initial commissioning in Easy Startup mode
NOTICE
►Before installing the accessories, check whether they are suitable for use with the selected variant.
►For information about the complete range of accessories, refer to our website.
►Please contact Zimmer Customer Service if you have any questions.
11.1.1 Setting the IP address
►Dene the IP address for the servo amplier (default: 192.168.0.1).
►Enter the IP address for the servo amplier manually via the control panel on the converter.
►Enable the IP range on your PC for this purpose.
►Press the "Enter" button in the main eld of the control panel.
►Select "Ethernet" by pressing the arrow button .
►Press the "Enter" button.
ÖThe selection has been conrmed.
►Press the "Enter" button.
ÖThe IP address menu opens.
►Set the IP address by pressing the arrow button  .
►Press the "Enter" button.
ÖThe input has been conrmed.
►Restart the servo amplier.
INFORMATION
►Enter the IP address in the IndraDrive Ds software and the PC/laptop (programming device).

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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
11.1.2 Setting the IP address
INFORMATION
The IndraWorks Ds or IndraWorks Engineering software must be available to carry out initial commissioning.
►Carry out the following information and application steps for initial commissioning using the IndraWorks Ds
14V24 software.
ÖThe work eld or sequence of operations may be different in different software versions.
►Please consult the software manufacturer to learn how to use the software version available to you.
ÖZimmer GmbH shall not be liable in case of damage from improper or erroneous function.
►Start the IndraWorks Ds software.
►Click the "Search" button.
►Search for connected nodes (IndraDrive Cs).
ÖFound nodes appear in the "Connection Selection" window.
►Enable the desired nodes in the "Connect" column.
ÖThe IP address must match.
►Click the "OK" button.
ÖThe connection to the controller is established.

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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
ÖThe main software window opens after successfully connecting.
• The navigation pane for displaying and editing various functions of the system is on the left.
• When starting, the "Axis Status" window appears to the right of the navigation pane.
• Possible error messages are displayed in the menu bar.

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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
11.1.2.1 Reading out the rmware status of the controller
NOTICE
The controller's rmware must correspond to the rmware of the parameter sets.
►Select "Diagnostics" in the menu bar.
►Select "Electr. Type plate".
ÖThe rmware status appears.

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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
11.1.2.2 Loading axis-specic parameter sets
►Select the correct parameter set.
• The parameter set designation consists of the following:
• Product type (e.g. DES)
• Motor type (e.g. M5)
• Firmware version (e.g. MPB-18V etc.)
• Mode (e.g. "EasyStart")
Öthe unit can be operated in this mode.
• Available parameter sets:
• DES140_M5_MPx18_EasyStart.par
• DES190_M5_MPx18_EasyStart.par
►Select "Conguration" from the menu bar.
►Select "Load" from the menu.
ÖThe parameter loading window opens.
►Select the suitable parameter set.
►Click the "Load" button.
ÖThe loading process into the controller begins.

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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
ÖThe software noties you before transmitting that the controller must be in conguration mode.
ÖIf the controller is already in conguration mode, this message will not appear.
After the parameter set has been successfully transmitted to the controller, it must be restarted. To do this, you can either
briey disconnect the controller's power supply or use the software to reboot.
►Select "Master Communication" in the navigation pane.
ÖThe "Master Communication Basic Settings" appear on the right side of the window.
►Click the "Reboot" button.
ÖThe restart of the controller starts.
No "BUS connection (Master Communication)

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INSTALLATION AND OPERATING INSTRUCTIONS: GEH8000
ÖAfter a short time, the main window appears on the monitor.
ÖIf the transmission was successful, the name of the parameter set appears in the navigation pane.
• DES140_M5_MPx18_EasyStart.par
• DES190_M5_MPx18_EasyStart.par
►Eliminate all errors so that the unit can be moved.
ÖCurrent error messages are displayed in the "Axis Status" window.
ÖError messages can be acknowledged using the "Clear Error" button.