Zimmer WWR Series User manual

INSTALLATION AND
OPERATING INSTRUC-
TIONS
WWR series
Pneumatic tool changer
DDOC00227
THE KNOW-HOW FACTORY
www.zimmer-group.com

2
DDOC00227 / n DE / 2020-11-26
Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ●[phone] ● [phone] ● www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Tool changer, pneumatic, WWR series

INSTALLATION AND OPERATING INSTRUCTIONS: Tool changer, pneumatic, WWR series
3
DDOC00227 / nDE / 2020-11-26
Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ●[phone] ● [phone] ● www.zimmer-group.com
Content
1. Supporting documents.......................................................................................................................................................4
2. Safety notes .........................................................................................................................................................................4
3. Proper use............................................................................................................................................................................5
4. Personnelqualication .......................................................................................................................................................5
5. Product description.............................................................................................................................................................5
5.1 Forces and torques..............................................................................................................................................................................................5
5.2 Type plate .............................................................................................................................................................................................................5
5.3 Protection class....................................................................................................................................................................................................6
6. Function ...............................................................................................................................................................................6
6.1 Technical data ......................................................................................................................................................................................................7
7. Installation............................................................................................................................................................................7
7.1 Safety notes..........................................................................................................................................................................................................7
7.2 General installation information..........................................................................................................................................................................7
7.3 Installingthexedpart ........................................................................................................................................................................................8
7.4 Installing the loose part .......................................................................................................................................................................................8
7.5 Installing the pneumatic connections ................................................................................................................................................................8
7.6 Installing accessories ..........................................................................................................................................................................................9
8. Sensing ..............................................................................................................................................................................10
8.1 Piston position sensing .....................................................................................................................................................................................10
8.2 WWR40F, WWR50F, WWR63F design sizes ...................................................................................................................................................10
8.3 Design size WWR80F ........................................................................................................................................................................................11
8.4 Design size WWR100F ......................................................................................................................................................................................12
8.5 Design size WWR125F ......................................................................................................................................................................................13
8.6 Design size WWR160F ......................................................................................................................................................................................14
8.7 Inductiveproximityswitch.................................................................................................................................................................................15
8.8 Storage station ...................................................................................................................................................................................................16
9. Maintenance ......................................................................................................................................................................17
10.Accessories/scope of delivery.........................................................................................................................................17
11.Transportation/storage/preservation ..............................................................................................................................17
12.Decommissioning and disposal.......................................................................................................................................17
13.Declaration of Incorporation.............................................................................................................................................18

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DDOC00227 / n DE / 2020-11-26
Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ●[phone] ● [phone] ● www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Tool changer, pneumatic, WWR 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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). Only those
documentscurrentlyavailableonthewebsitearevalid.
• Catalogs,drawings,CADdata,performancedata
• Information on accessories
• Detailed installation and operating instructions
• Technical data sheets
• GeneralTermsandConditionsofBusinesswithspecicationsforthewarrantyentitlement
2. Safety notes
CAUTION:
1. Installation,commissioning,maintenanceandrepairsmayonlybeperformedbyqualiedspecialistsinac-
cordancewiththeseinstallationandoperatinginstructions.
2. Thetoolchangerisstate-of-the-art.Itismountedtoindustrialmachinesandisusedtoholdtools.Thefollow-
ingareexamplesofsituationsinwhichthetoolchangermaycauseahazard:
• The tool changer is not properly mounted, used or maintained.
• The tool changer is not used for its intended purpose.
• Localregulations(legislation,ordinances,guidelines),suchastheECMachineryDirective,accidentpre-
vention regulations and the installation and operating instructions, are not observed.
3. Thetoolchangermaybeusedonlyinaccordancewithitsproperuseandtechnicaldata.ZimmerGmbH
shall accept no liability for any damage caused by improper use.
4. AnyuseotherthantheintendeduserequireswrittenapprovalfromZimmerGmbH.
5. Do not reach into the operating range of the attached tools.
6. Makesurethatthepowercablesaredisconnectedbeforeyouinstall,retool,maintainorrepairthetool
changer.
7. Intheeventofmaintenance,retrottingorworkingwithattachments,removethetoolchangerfromthema-
chineandperformtheworkoutsidethedangerzone.
8. Whencommissioningortesting,makesurethatthetoolchangercannotbeactuatedbymistake.
9. Modicationstothetoolchangersuchasaddingdrilledholesorthreads,maybemadeonlywithpriorap-
provalfromZimmerGmbH.
10.Thespeciedmaintenanceintervalsaretobeobserved;alsorefertothe"Maintenance"section.Whenusing
thetoolchangerunderextremeconditions(seeItem11),themaintenanceintervalmustbeadapteddepend-
ingontheextentofthecontamination.Pleasecontactourhotlineforthispurpose.
11.Useofthetoolchangerunderextremeconditions,suchasaggressiveliquidsandabrasivedusts,issubject
topriorapprovalfromZimmerGmbH.

INSTALLATION AND OPERATING INSTRUCTIONS: Tool changer, pneumatic, WWR series
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DDOC00227 / nDE / 2020-11-26
Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ●[phone] ● [phone] ● www.zimmer-group.com
3. Proper use
NOTICE:
Thetoolchangeristobeusedonlyinitsoriginalstatewithitsoriginalaccessories,withoutanyunauthorized
changesandwithinthescopeofitsdenedparametersofuse.
ZimmerGmbHshallacceptnoliabilityforanydamagecausedbyimproperuse.
Thetoolchangermayonlybeusedintheoriginalconditionwithoriginalaccessories.
Useoutsideofthedenedparametersisnotpermitted.Unauthorizedelectricalormechanicalmodicationsmustnotbe
made.
Thetoolchangerisdesignedexclusivelyforpneumaticoperation.Itisnotsuitedforoperationwithothermediasuchas
liquidsorgases.Thexedpartofthetoolchangerisintendedtobeusedinclosedroomsforhandlingandholdingtool
changerloosepartswithtoolsmountedthereon.Forcesandtorquesthatthetoolchangerhastoabsorbmustnotexceed
the recommended parameters.
For the supply of pneumatic, hydraulic or electrical actuators, several transmission elements are available depending on the
designsize.Optionally,themediatransmissioncanbesetupwithtransmissionelementsatcorrespondinginterfaceson
the tool changer.
4. Personnel qualication
DANGER:
Interventionisnotpermittedandcanleadtoseriousinjuries!
ÖWarranty and disclaimer
Installation,commissioningandmaintenancemayonlybeperformedbyqualiedpersonnel.
These personnel must have read and understood the installation and operating instructions in full.
5. Product description
WARNING:
Non-compliancemayresultinsevereinjuries!
Dangerofinjuryifthetoolchangerisnotoperatedasintended!
Thetoolchangermustneverbeoperatedwithoutcompressedair.Thebuilt-inspringisusedexclusivelyforlock-
ingthedeviceintheeventofpowerloss.
►Alwaysoperatethetoolchangeratanoperatingpressureofbetween4and10bar.
5.1 Forces and torques
INFORMATION:
Forinformationonforcesandtorques,pleasevisitourwebsite.
ZimmerCustomerServiceisavailabletoprovideyouwithassistanceifyouhaveanyfurtherquestions.
5.2 Type plate
A type plate is attached to the housing of the energy element.
Theserialnumberandthearticlenumberareshownonthistypeplate.
►Theserialnumbershouldbeassignedtotheproject.
ÖArticlenumber:dl
ÖSerialnumber:dm
INFORMATION:
Please state the serial number in the event of damage or a complaint.
ZimmerCustomerServiceisavailabletoprovideyouwithassistanceifyouhaveanyfurtherquestions.

6
DDOC00227 / n DE / 2020-11-26
Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ●[phone] ● [phone] ● www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Tool changer, pneumatic, WWR series
5.3 Protection class
NOTICE:
The tool changer achieves protection class IP64 in all mounted positions of installation.
6. Function
Thetoolchangerisatwo-piecemachineelement.Thexedpart4is mounted on a handling system.
The loose part blismounteddirectlyonthetool.Theconnectionofthetwoelementsisformtandfrictionallytusing
thelockingbolts6inthelockingsleeve7.Therequiredstrokeisgeneratedbyadouble-actingpneumaticrotorcylinder
2. An integrated spring 3actsasanenergystoreandpreservesthecapabilityofthetoolchangertobelockedinthe
eventofapowerfailureorinterruption.
Axedpartcanbeoperatedwithasmanyloosepartsasdesired.Thissignicantlyreducesset-uptimesfortoolexchang-
ing.
1Type plate
2
Pneumatic connection
A = locked
B = unlocked
3Robot ange/xed part
4Locking bolt
5Tool ange/loose part
6Integrated pneumatic feed-through
7Locking sleeve
8Drive
9Integrated spring
bl Piston position sensor
bm Energy element
Fig.1:WWRseriestoolchanger
1
2
3
4
6
5
7
Fig.2:CutawayviewoftheWWRseriestoolchanger
74 bl
8 9 3
6bm

INSTALLATION AND OPERATING INSTRUCTIONS: Tool changer, pneumatic, WWR series
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DDOC00227 / nDE / 2020-11-26
Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ●[phone] ● [phone] ● www.zimmer-group.com
6.1 Technical data
INFORMATION:
Fortechnicaldata,pleasevisitourwebsite.
Thisdatavarieswithintheseries,dependingonthespecicdesign.
ZimmerCustomerServiceisavailabletoprovideyouwithassistanceifyouhaveanyfurtherquestions.
7. Installation
7.1 Safety notes
CAUTION:
Non-compliancemayresultinsevereinjuries!
Riskofinjuryintheeventofunexpectedmovementofthemachineorsystemintowhichthetoolchanger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.
NOTICE:
Whenusingthehose-freeconnections,theO-ringsmustbeinsertedintothecustomer-preparedpocketsofthe
holes on the mounting surface before installation.
Non-compliancemayresultinmaterialdamage
Itismandatorytoobservethespeciedscrewlength.
7.2 General installation information
Thegrippermustbeinstalledonamountingsurfaceinaccordancewiththespecicationsforatness.
Length < 100 mm permittedatnessimperfection<0.02mm
Length > 100 mm permittedatnessimperfection<0.05mm
ÖMountingscrewsarenotincludedinthescopeofdelivery.
ÖStrengthclassofthemountingscrews≥8.8(DINENISO4762)
ÖObservethetighteningtorqueofthemountingscrews.
ÖMakesurethemountingsurfaceissu󹱺cientlyrigidandat.
ÖRefertothetechnicaldatasheetfortheexactpositions.

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DDOC00227 / n DE / 2020-11-26
Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ●[phone] ● [phone] ● www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Tool changer, pneumatic, WWR series
7.3 Installing the xed part
Thefollowingworkstepsmustbeobserved
wheninstallingthexedpart3:
►Installationfromthexed-partside,against
thehandlingsystem:
►Insertthestraightpinintothedesignatedts
on the tool changer.
►Insert the centering diameter on the robot
ange
ÖScrew-indepth=min.1.5xØ.
5
bn
bo
3
7.4 Installing the loose part
Thefollowingworkstepsmustbeobserved
wheninstallingtheloosepart3:
►Installation from the tool side and into the
tapped holes bn:
►Insertthestraightpinintothedesignatedts
on the tool changer.
►Position the loose part on the tool
ÖScrew-indepth=atleast1.5xØ.
7.5 Installing the pneumatic connections
Connectionwiththeidentier"A":locked
Connectionwiththeidentier"B":unlocked
ThefollowingisadescriptionoftwopossibilitiesforoperatingthetoolchangerinaccordancewiththerulesoftheDINEN
ISO13849-1standardindifferentcontrolcategories,allowingtherequiredperformancelevel(PL)tobereached:
Control category 1 (recommendation):
• Proven components
• Zerodefectdetection
• PL c accessible
Thetoolchangeriscontrolledviaa5/2-way
directional valve.
To implement the safety function, the use of
"provencomponents,"asdescribedinSection
6.2.4ofENISO13849-1,issu󹱺cient.
Asimplenalpositioncheckispossiblewiththe
S3andS4magneticeldsensorsdirectlyatthe
toolchanger(seeaccessories).
1
2
3
4
5
WWR
verriegelt
entriegelt
Steuersignal
„entriegelt“
Steuersignal
„verriegelt“
V2
A
B
S3
S4
S3 S4
GG
WWR
AB
entriegelt
verriegelt

INSTALLATION AND OPERATING INSTRUCTIONS: Tool changer, pneumatic, WWR series
9
DDOC00227 / nDE / 2020-11-26
Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ●[phone] ● [phone] ● www.zimmer-group.com
Control category 3 (recommendation):
• Dual-channel
• Degreeofdiagnosticcoverage:medium
• Useof2mono-stablevalves
Öthisimplementsthesafetysub-functions
"reversing"and"unexpectedstartup"
(unlock)
ÖPL d accessible
• Additional storage space control or tool
encoding is possible by means of optional
transponders.
• Asimplenalpositioncheckispossiblewith
theS3andS4magneticeldsensorsdirectly
atthetoolchanger(seeaccessories).
7.6 Installing accessories
NOTICE:
Beforeinstallinganaccessory,makesureitissuitableforusewiththeselectedvariant.
Forinformationonallavailableaccessories,pleasevisitourwebsite.

10
DDOC00227 / n DE / 2020-11-26
Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ●[phone] ● [phone] ● www.zimmer-group.com
INSTALLATION AND OPERATING INSTRUCTIONS: Tool changer, pneumatic, WWR series
8. Sensing
8.1 Piston position sensing
Thesensorsforsensingthepistonpositionaretheretoprovidesafety.Thefollowingoperationmaybestartedonlyifa
clear signal displays the respective position of the piston. The sensors are not absolutely necessary for the function of the
toolchanger.Theinstallationofthesensorstakesplaceinanumberofwaysaccordingtodesignsizes-seethefollowing
section.
8.2 WWR40F, WWR50F, WWR63F design sizes
1-point sensor
• WWR40F ÖZUB0015
• WWR50F ÖZUB0016
• WWR63F ÖZUB0017
2-point sensor
ÖWWR40F ÖZUB088929
ÖWWR50F ÖZUB088928
ÖWWR63F ÖZUB088927
Example:
►Insert the sensors cm into the sensor holder cn.
►Slide the sensor holder cnwiththesensorscm into the sensor bay cl.
►Secure the sensor holder cn in the sensor bay clusingthegrubscrewco(seearrowinthegures).
ZUB088929ZUB0015WWR40F-B
cl
co
cmcn
cm
cn co co