Zimmer GPD5000IL, GPP5000IL Installation And Operating Instructions

INSTALLATION AND

OPERATING INSTRUCTIONS

Handling
technology

GPP/GPD5000IL series

"The Hybrid"

THE KNOW-HOW FACTORY

Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ● Phone: [phone]

Link

IO-

www.IO-Link.com

●

Fax: [phone] ● www.zimmer-group.de

INSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic gripper, intelligent GPP/GPD5000IL series

Content:

1. Supporting documents 3

2. Proper use 3

3. Personnel qualication 3

4. Safety notes 3

5. Product description 4

5.1 GPP5000IL function (NO/NC) 4

5.2 GPD5000IL function (NO/NC) 5

5.3 GPP/GPD5000IL function (N) 5

6. Installation 5

6.1 Safety notes 5

6.2 Installing the gripper 5

6.3 Installing the gripper ngers 6

6.4 Static charge 6

6.5 Inuencing the position sensor 6

6.6 Pneumatic connection 6

7. Commissioning 6

7.1 IO-Link commissioning 6

7.2 Control 7

7.3 LED display 8

7.4 Process data 8

7.5 Control with cyclical process data 9

7.5.1 Procedure for data transfer 9

7.5.2 "ControlWord" parameter 10

7.5.3 "DeviceMode" parameter 11

7.5.4 "WorkpieceNo." parameter 11

7.5.5 "TeachPosition" parameter 12

7.5.6 "PositionTolerance" parameter 12

7.5.7 "StatusWord" parameter 13

7.5.8 "Diagnosis" parameter 13

7.5.9 "ActualPosition" parameter 14

7.6 Sensing of end positions 14

7.7 Service parameters 14

7.7.1 StatusWord 0x40 14

7.7.2 Diagnostics 0x41 14

7.7.3 Cycle counter 0x42 15

7.7.4 System temperature 0x43 15

7.7.5 ControlWord 0x44 15

7.7.6 Error code 0x45 15

7.7.7 Error code 0x46 15

7.7.8 Operating seconds counter 0x47 15

7.7.9 ActualPosition 0x100 16

7.7.10 TeachPosition 0x101 16

7.7.11 WorkpieceNo. 0x102 16

7.7.12 DeviceMode 0x103 16

7.7.13 PositionTolerance 0x104 16

7.7.14 Current operating pressure 0x110 16

7.7.15 Pressure switch bottom 0x111 17

7.7.16 Pressure switch top 0x112 17

7.7.17 Pressure hysteresis 0x113 17

7.7.18 Base/Work position switching thresholds 0x114 17

7.7.19 Movement detection 0x115 17

8. Error diagnostics 18

9. Accessories 19

10. Glossary 20

11. Maintenance 21

12. Fault exclusion 21

13. Installer's Declaration (in accordance with the Machinery Directive) 22

14. Declaration of Conformity (in accordance with the EMC Directive) 23

15. Your notes 24

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Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ● Phone: [phone]

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Fax: [phone] ● www.zimmer-group.de

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INSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic gripper, intelligent GPP/GPD5000IL series

1. Supporting documents

Note:

The following documents are available for download on our website.
Only the documents currently available on the website are valid.

• Catalog

• Drawings, performance data, information about accessory parts, etc.

• General terms and conditions, including warranty information

2. Proper use

Note:

The gripper should only be used in its original state with its original accessories, without any 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 gripper is designed exclusively for operation using a 24 V DC power supply.
The operating pressure is in the range of 3-8 bar for standard grippers and 4-7 bar for the respective NC/NO versions.

The gripper is used as dened under "Proper use" in enclosed rooms to temporarily grip, handle and hold parts.

The gripper is not suitable for clamping workpieces during a machining process.
Direct contact with perishable goods/food is not permitted.

3. Personnel qualications

Installation, commissioning and operation may be undertaken by trained specialists only. They must have read and understood the
installation and operating instructions in full.

4. Safety notes

1. Installation, commissioning, maintenance and repairs may only be performed by qualied experts in accordance with

these installation and operating instructions.

2. The gripper is state-of-the-art. It is tted to industrial machines and is used to hold workpieces. The following are ex-

amples of situations in which the gripper may cause a hazard:

- the gripper is not properly tted, used or maintained

- the gripper is not used for its intended purpose

- failure to observe the local regulations (legislation, guidelines, directives), such as the EC Machinery
Directive,

- the Accident Prevention Regulations (UVV) and the assembly and operating instructions

are not observed.

3. The gripper 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 proper use requires written approval from Zimmer GmbH

5. Make sure that the energy supply is disconnected and before you install, retool, maintain or repair the gripper.

6. In case of maintenance, renovation or expansion work, remove the gripper from the machine and carry out the work

outside the danger zone.

7. When commissioning or testing, make sure that the gripper cannot be actuated by mistake.

8. Modications to the gripper, such as adding drill holes or threads, may be made only with prior approval from Zimmer

GmbH.

9. The specied maintenance intervals and compressed air quality specications are to be observed; also refer to the

Maintenance section. When using the gripper under extreme conditions (see Item 11), the maintenance interval must
be adapted depending on the extent of the contamination. Please contact our hotline for this purpose.

10. Use of the gripper under extreme conditions, such as aggressive liquids and abrasive dust, is subject to prior approval

from Zimmer GmbH

11. When disassembling grippers with integrated springs, exercise increased caution because spring tension is always

present.

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Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ● Phone: [phone]

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Fax: [phone] ● www.zimmer-group.de

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INSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic gripper, intelligent GPP/GPD5000IL series

5. Product description

• Alternating ventilation moves the internal pneumatic piston 1

up and down.

• The power generated in this process is transferred 2 to

the gripper jaws 3 via a kinematic system to produce the
gripping force.

• The double-lip seal 5 reliably prevents lubricant from

escaping and guarantees protection with IP 64 from the
exterior.

• Integrated gripping force safety device 4 (only for NC / NO)

Spring inserted in the cylinder chamber used for energy
storage

• The pneumatic piston is controlled by integrated

3/2 NC 24 V DC directional valves. 6

• Communication is carried out over an IO-Link interface 7.

3

2

5
4
1

6
7

The 3-jaw concentric grippers from the GPD5000IL series
operate according to the same principle.

3
2

5
4
1

7
6

INFORMATION:
Useofltered,compressedair,oil-free,inaccordancewithENISO8573-1,Class3.4.3

Note:

The gripping force safety device with an integrated spring as an energy storage unit is only available

fortheNCandNOversions.TheNversionhasno gripping force safety device in either gripping direction.

5.1 GPP5000IL function (NO/NC)

The gripper ngers of the parallel gripper are arranged successively on two shared

steel guide rails and can be moved alongside each other.

Compressed air that moves a piston is used to supply power.
The stroke movement of the piston is diverted to both gripper jaws via a connect­ing rod.
This generates the movement of the gripper jaws.

An internal spring is used to retain the gripping force when there is a drop in pres­sure.

The gripper is suitable for outward gripping. (NO = normally open)

The gripper is suitable for inward gripping. (NC = normally closed)

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Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ● Phone: [phone]

NO NC

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INSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic gripper, intelligent GPP/GPD5000IL series

5.2 GPD5000IL function (NO/NC)

The gripper ngers of the three-jaw gripper are each positioned between two

steel guide rails.

Compressed air that moves a piston is used to supply power.
The stroke movement of the piston is diverted to both gripper jaws via a
connecting rod.
This generates the movement of the gripper jaws

An internal spring is used to retain the gripping force when there is a drop in
pressure.

The gripper is suitable for outward gripping. (NO = normally open)

The gripper is suitable for inward gripping. (NC = normally closed)

NO

5.3 GPP/ GPD5000IL function (N)

The gripper ngers of the three-jaw gripper are each positioned between two

steel guide rails.

Compressed air that moves a piston is used to supply power.
The stroke movement of the piston is diverted to both gripper jaws via a
connecting rod.
This generates the movement of the gripper jaws.

There is no gripping force retention in the event of a pressure or voltage loss.

The gripper is suitable for outward or inward gripping.

NC

6. Installation

6.1 Safety notes

CAUTION:
Bleed the pressure supply and switch o the power supply for the electronics before any assembly, installation

or maintenance work.

► Risk of injury

6.2 Installing the gripper

The gripper can be installed from several sides on a mounting surface that meets the specications for evenness.

If the length of the mounting surface is <100 mm, the permitted unevenness is <0.02 mm.
If the length of the mounting surface is >100 mm, the permitted unevenness is <0.05 mm.

The following work steps are to be carried out to install the gripper:

► Insert centering sleeves/alignment pins into the provided matching parts on the gripper.
► Position the gripper on the intended mounting surface using the centering sleeves/alignment pins.
► Secure the gripper with cylinder screws of strength class 8.8.
► Connect the M12 5-pin supply cable for the IO-Link Port Class B.

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Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ● Phone: [phone]

●

Fax: [phone] ● www.zimmer-group.de

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INSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic gripper, intelligent GPP/GPD5000IL series

6.3 Installing the gripper ngers

Before installing the gripper ngers, make sure they are of a suitable length for the selected gripper variant.

The following work steps should be performed to install the gripper ngers:

► Insert centering sleeves into the provided matching parts on the gripper jaws
► Position the gripper ngers on the gripper jaws using the centering sleeves
► Secure the gripper ngers using cylinder screws with strength class of at least 8.8

NOTE:

For details on the tightening torque, screw diameter and maximum weight and length of the gripper ngers, refer to

the product data sheet.

6.4 Static charge

Many dierent non-conductive parts move around in the gripper. As a consequence, high voltages can arise as a result of

electrostatic charges, which can also discharge to the component. If this is not desired, it must be ensured that the gripper can be
discharged of electrostatic charges via its mounting surface.

NOTE:

Grounding the gripper attachment is recommended if parts sensitive to electrostatic discharge come into contact

with the gripper.

6.5 Inuencing the position sensor

In the adjacent gure, an area in which no magnets or components with

ferromagnetic properties may be fastened is marked.

This can have a signicant inuence on accuracy of the position sensor and/

or result in a malfunction of the position sensor.

NOTE:

The position sensor itself must never be covered up by fer-

romagnetic attachment or design elements.

6.6 Pneumatic connection

7 Connection "R": Exhaust air with

mounted silencer

8 Connection "S": Exhaust air with

mounted silencer

9 Connection "P": Compressed air

8
9
7

INFORMATION:
The pneumatic connections A and B right on the gripper are not used and are closed.

For applications with an IP64 protection class, we recommend installing hoses on the "R" and "S" connections
for diverting the exhaust air to prevent the condensate from damaging the silencers.

7. Commissioning

7.1 IO-LINK commissioning

► Connecting the gripper to the IO-Link master
► Ensuring the supply voltage (for Port Class A additional supply via Y-cable)

8
7
9

Pin Color Function Explanation

1 Brown

2 White

3 Blue

4 Black

5 Gray

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Zimmer GmbH ● Im Salmenkopf 5 ● 77866 Rheinau, Germany ● Phone: [phone]

+24V DC sensor Power supply for IO-Link communication

+24V DC actuator Actuator supply voltage

GND sensor Sensor 0 V DC supply voltage

C/Q IO-Link communication

GND actuator Actuator 0 V DC supply voltage

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INSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic gripper, intelligent GPP/GPD5000IL series

► Importing the IODD (device description) into the control system

 Go the website https://ioddnder.io-link.com
 Search for "Zimmer Group" in the search window that appears
 Select the desired device and download the corresponding *.zip les
 The complete content of the zip les is required for importing within the control

INFORMATION:
The IODD le can also be downloaded from

the product datasheet on our website.

Picture shown as example

When the hardware conguration is complete and the IO-Link connection to the gripper is established,

some data must already be visible in the process input data.
 Some control systems demand a byte swap to bring this process data into a sequence that makes sense.

► To determine whether a byte swap is necessary, you can check Bit 6 [GripperPLCActive] in the "StatusWord".
► For this purpose, it is necessary to determine whether bit 6 [GripperPLCActive] is active in the rst or second status byte.

 This bit must be the only one active in this byte.
 If bit 6 in the rst byte is active, a byte swap still has to be applied here.
 If bit 6 in the second byte is active, the bytes already have the correct sequence and you can continue with the rest of

the commissioning.

INFORMATION:
It is mandatory to carry out a verication of the process data

The gripper is controlled via IO-Link by means of the cyclical process data and the acyclical service data, with a cycle time of 5 ms.
During a communication cycle the IO-Link master sends 8 bytes to the gripper and receives 6 bytes of process data.

If the gripper is operational, a "1" must be sent in the "ControlWord" during a cold start for safety reasons. This "1" tells the gripper to
accept the current values that have been transmitted in the process data.
The gripper is now ready for operation. The gripper then moves to the proper position after receiving the corresponding command
in the "ControlWord" (decimal 256 or 512).

The gripper features bidirectional behavior. This means that the gripper cannot position itself on intermediate values. Each move­ment command is executed to the maximum possible position.

INFORMATION:
For more information, refer to the "StatusWord" section

7.2 Control

The gripper is controlled via IO-Link by means of the cyclical process data, with a minimum cycle time of 5 ms. During a communi­cation cycle the IO-Link master sends 8 bytes to the gripper and receives 6 bytes of process data.

Fieldbus or PLC

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IO-Link master

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INSTALLATION AND OPERATING INSTRUCTIONS: Pneumatic gripper, intelligent GPP/GPD5000IL series

The gripper is connected to the IO-Link master by a 5-pin M12 connector, in accordance with Port Class B. In doing so,
pin 1 (24 VDC) and pin 3 (0 VDC) are for supplying power.
Pin 2 (24 VDC) and pin 5 (0 VDC) are required for auxiliary power supply to the gripper.
Pin 4 is used for IO-Link communication between the gripper and the IO-Link master.

The actuator supply voltage acts on the internal valves. As a result of this voltage being switched-o, the valves will no longer be
able to be switched. In the event of an emergency (switch-o of the actuator voltage), the gripper bleeds the pistons and, depending

on the design of the gripper (N, NC, NO), there is no gripping force safety device present.

7.3 LED display

The color of the LED reects the status of the gripper.

Status Function

Green

On continuously Teach position

Flashing

Not currently assigned

Blue

On continuously Base position/Work position

Flashing

Not currently assigned

Red

On continuously The gripper has a fault

Flashing No IO-Link connection is available

Orange

On continuously Gripper is in undened position

Flashing

Not currently assigned

7.4. Process data

It is possible to control the gripper solely by the process data transmitted in each IO-Link cycle. To use this method of control,
a "0" must be continuously transmitted in the workpiece number.
As a result, the currently applied process data is used as a process parameter.

Unlike the gripping force and the "TeachPosition," the "ControlWord" and the "WorkpieceNo." are always valid!
If the gripper is controlled via the stored workpiece records, the values entered there are used as the current values. As a result, the
process data words "gripping force" and "TeachPosition" are devalued. The "WorkpieceNo." parameter is to be recognized as being
a selector switch.

Name Data type

ControlWord

DeviceMode.

WorkpieceNo.

TeachPosition

RESERVE

PositionTolerance

Outputs

UINT 16

UINT 8

UINT 8

UINT 16

UINT 8

UINT 8

GPP/GPD5000ILControl system

Inputs

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Name Data type

Status

Diagnostics

ActualPosition

UINT 16

UINT 16

UINT 16

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