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Zimmer ZK1000 Series - User Manual

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INSTALLATION AND OPERATING INSTRUCTIONS: Cutting tongs, pneumatic, ZK1000 series
Zimmer GmbH
●
Im Salmenkopf 5
●
77866 Rheinau
●
Germany
●
+49 7844 9138 0
●
+49 7844 9138 80
●
www.zimmer-group.com
Installation and
operating instructions
ZK1000 series
DDOC01013
Index a
EN/2022-19-07
Im Salmenkopf 5
77866 Rheinau
Germany
+49 7844 9138 0
+49 7844 9138 80
www.zimmer-group.com
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 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 to industrial machines and is used to hold tools.
The product can only become a source of hazard if, for example:
• 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 scope of its dened parameters for use.
Zimmer GmbH shall accept no liability for any damage caused by improper use.
The product is designed exclusively for pneumatic operation.
The product is designated for use in enclosed rooms for separating dened materials.
Direct contact with perishable goods/food is not permitted.
It is not suited for operation with other media such as liquids or gases.
4. Personnel qualication
Installation, commissioning and maintenance may only be performed by qualied personnel. These persons must have read and
understood the installation and operating instructions in full.
5. Product description
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 product.
The conrmation number and the article number are indicated on this type plate.
The conrmation number should be assigned to the project.
• Article number: am
• Conrmation number: an
INFORMATION
Please state the conrmation 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. Function
The function is based on a single-acting vented pneumatic piston with spring return. As a result of its structure, the ZK1000
series product reduces interference contours, thereby enabling simple integration into the machine design.
The ZK1000 series makes it possible to use different cutting geometries and materials.
The ZK1000 series has an integrated magnetic eld sensor. This ensures process reliability for sensing the positions and
transmitting them to the control system.
1
Power supply
ZK1000 product series
2
1
3
4
5
6
2
Mounting and positioning
3
Cutting insert
4
Mounting clamp for magnetic eld sensor
5
Magnetic eld sensor
6
Housing
7. Installation
7.1 General installation information
WARNING
Risk of injury in case of unexpected movement of the machine or system into which the product 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 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 power supply for any residual energy.
NOTICE
Switch off the power supply before any assembly, installation or maintenance work.
The product must be installed on a suitable mounting surface in accordance with the atness specications.
Ö Permissible atness imperfection: 0.03 mm
Ö The locknut is included in the scope of delivery.
Ö Strength class of the locknut at least 8.8 DIN EN ISO 4762
Ö Observe the tightening torque of the locknut.
Ö Zimmer GmbH recommends verifying the permitted load-carrying capacity of the required screw connections in accordance
with VDI 2230.
Ö Make sure the mounting surface is su󹱺ciently rigid and at.
Ö The exact positions can be found on the technical data sheet on our website www.zimmer-group.com.
7.2 Installing mechanic
The gripper can be installed on the mounting piece using the
screw thread 2and the locknutbl.
The following work steps must be observed during installation:
► Guide the product into the borehole on the mounting piece.
Ö It is held using the mating part bp.
► Secure the product using the locknut bl.
Ö Attach the locknut blso that it is hand-tight.
► Align the product.
► Tighten the locknut blto the specied tightening torque.
2
bl
9
bp
7.3 Installing the power supply
Insert the screw connection 9into the designated connection.
NOTICE
Close off unused pneumatic connections with dummy plugs.
The authorized pneumatic connections that are available can be found in the accessories list, which is available on
our website.
The necessary ordering information can also be found there.
Ö Use compressed air in accordance with DIN ISO 8573-1 [4:4:4].
7.4 Installing/disassembling the cutting insert
7.4.1 Installation
The following work steps must be observed when installing the
cutting insert:
► Switch off the power supply to the product.
► Check the power supply for any residual energy.
► Guide the cutting insert bninto the housing 6.
► Secure the cutting insert bnusing the bearing pin bo.
► Secure the bearing pin bousing the lock washers bm.
7.4.2 Uninstallation
The following work steps must be observed when disassembling
the cutting insert:
► Switch off the power supply to the product.
► Check the power supply for any residual energy.
► Remove the lock washers bm.
► Pull out the bearing pin bo.
Ö In doing so, hold the cutting insert bnsecurely.
► Take the cutting insert bnout of the housing 6.
bm
bn
bo
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Overview

  1. Function Description
  2. Important Technical Specifications
  3. Usage Features
  4. Maintenance Features

The Zimmer ZK1000 series pneumatic cutting tongs are designed for precise and efficient cutting operations in industrial settings. This device is an incomplete machine, intended for integration into a larger machine or system.

Function Description

The ZK1000 cutting tongs operate pneumatically, utilizing compressed air to actuate the cutting mechanism. The device is designed to cut various materials, with specific cutting diameters detailed in the technical specifications. Its modular design allows for the integration of accessories such as sensor brackets, which enable automated monitoring of cutting operations. The tongs are equipped with a power supply connection, pneumatic connections, and, depending on the variant, communication connections for integration into automated systems. The cutting process involves inserting the material into the tongs, which then apply a controlled cutting force. The device is designed for high-cycle operations, with a guaranteed maintenance-free period of up to 5 million cycles under optimal conditions.

Important Technical Specifications

The ZK1000 series is an incomplete machine as defined by the EU Machinery Directive 2006/42/EC (Annex II 1 B). It complies with basic requirements of this directive, including safety, health, and environmental protection.

  • Product Designation: Cutting tongs, pneumatic
  • Type Designation: ZK1000
  • Manufacturer: Zimmer GmbH, Im Salmenkopf 5, 77866 Rheinau, Germany
  • Cutting Diameters: Specific maximum cutting diameters are provided in the technical data sheet. These diameters are the maximum possible that can be accommodated and cut. Actual achievable diameters may be smaller depending on material properties and grades.
  • Power Supply: The device requires a power supply, the specifications of which are detailed in the technical documentation.
  • Pneumatic Connections: Standard pneumatic connections are used for compressed air supply.
  • Sensor Integration: The device supports the integration of magnetic field sensors (e.g., part 18) into sensor holders (e.g., part 17) and adapters (e.g., part 16) for monitoring cutting operations.
  • Operating Temperature: The device is designed to operate within a specified ambient temperature range.
  • Compressed Air Quality: For optimal performance and to ensure the maintenance-free cycle, compressed air must comply with DIN ISO 8573-1 quality class [4:4:4].

Usage Features

The ZK1000 cutting tongs are designed for ease of use and integration into industrial processes.

  • Modular Design: The device's modular construction allows for the easy installation of accessories, such as sensor brackets, to enhance functionality and automation.
  • Installation: Installation involves securing the device to a superordinate machine unit, connecting the power supply, pneumatic lines, and any communication connections. Specific instructions are provided for installing accessories like sensor brackets, which involve inserting the magnetic field sensor into its holder, then into an adapter, and finally securing the complete package to the product using a mounting clamp and screw.
  • Commissioning: Before commissioning, it is crucial to ensure that the machine or system into which the ZK1000 is installed complies with Directive 2006/42/EC and has an EC Declaration of Conformity.
  • Safety Features: The manual emphasizes the importance of safety, including switching off the power supply before any assembly, installation, or maintenance work. It also warns against risks of injury due to improper maintenance or non-compliance with safety regulations.
  • Troubleshooting: The manual provides guidance on troubleshooting common issues, such as the device not working, by checking power supply, pneumatic connections, and ensuring proper installation of accessories.
  • Documentation: Comprehensive documentation, including technical data sheets and detailed instructions, is available to support users. Zimmer Customer Service is also available for assistance.

Maintenance Features

The ZK1000 cutting tongs are designed for low maintenance, but specific guidelines must be followed to ensure longevity and optimal performance.

  • Maintenance-Free Operation: The product is guaranteed for up to 5 million cycles of maintenance-free operation under ideal conditions.
  • Maintenance Interval: The maintenance interval may be shortened under certain circumstances, including:
    • Operation with compressed air that does not comply with DIN ISO 8573-1 quality class [4:4:4].
    • Dirty operating environments.
    • Improper use or use that does not comply with power specifications.
    • Ambient temperatures above 60 °C.
  • Regular Visual Inspection: Despite being maintenance-free, regular visual inspections are recommended to check for any damage or contamination.
  • Authorized Personnel: Maintenance work must only be performed by trained personnel.
  • Power Disconnection: The power supply must be switched off before any maintenance work to prevent injury.
  • Unauthorized Disassembly: Unauthorized dismantling and reassembling of the product are strongly discouraged, as this can lead to complications, malfunctions, or damage, and may void manufacturer liability. Special installation equipment may be required for reassembly.
  • Storage: If the product is stored for an extended period, it must be kept in its original packaging in a dust-free, dry environment, away from direct sunlight, and within the specified temperature range. All components should be visually inspected, foreign substances removed, and pneumatic connections closed with suitable covers.
  • Transportation: The product should be transported in its original packaging. If installed on a superordinate machine, care must be taken to prevent uncontrolled movements. All connections should be checked after transport.
  • Decommissioning and Disposal: At the end of its operational life, the product can be completely disassembled and disposed of according to material groups. The power supply must be completely disconnected, and local environmental provisions, codes, and regulations for disposal must be observed.

Zimmer ZK1000 Series Specifications

General IconGeneral
BrandZimmer
ModelZK1000 Series
CategoryCutter
LanguageEnglish