Afag 50113773, Assembly And Operating Instructions Manual

Page 1: ...on of the Original Assembly Instructions EN SA 3 050 Order no 50113773 SA 6 100 Order no 50113798 SA 3 050 FL Order no 50471885 SA 6 100 FL Order no 50471888 SA 3 100 Order no 50113781 SA 6 200 Order no 50113800 SA 3 100 FL Order no 50471886 SA 6 200 FL Order no 50471889 SA 3 150 Order no 50251726 SA 6 300 Order no 50113804 SA 3 150 FL Order no 50471887 SA 6 300 FL Order no 50471890 ...

Page 2: ... regards Your Afag team Subject to modifications The modules have been designed by Afag Automation AG according to the state of the art Due to the constant technical development and improvement of our products we reserve the right to make technical changes at any time Copyright 2021 Afag Automation AG All contents of the present assembly and operating instructions in particular the texts photograp...

Page 3: ... 6 Personal protective equipment PPE 12 2 7 Changes modifications 12 2 8 General hazards residual risks 13 2 8 1 General hazards at the workplace 13 2 8 1 Mechanical hazards 14 2 8 2 Danger due to electricity 14 2 8 3 Noise hazards 14 2 8 4 Danger due to high temperatures 15 2 8 5 Safety labels warning symbols 15 3 Technical data 16 3 1 Telescope spindle axis SA 3 and SA 3 FL 16 3 1 1 Dimension dr...

Page 4: ...4 Afag standard controllers 34 6 4 1 SE 48 Controller 34 6 4 2 SE Power for control cabinet mounting 36 6 4 3 Servo controller 38 6 5 Programming of the telescope spindle axis 39 6 5 1 Safety instructions for programming 39 6 5 2 Programming 39 7 Commissioning 40 7 1 Safety instructions for commissioning 40 7 2 Preparatory activities for commissioning 41 7 3 Commissioning of the modules 41 7 4 Set...

Page 5: ...N SA 3 I SA 3 FL I SA 6 I SA 6 FL Edition 01 2021 Rev 4 5 5 56 10 Decommissioning disassembly disposal 50 10 1 Safety instructions for decommissioning and disposal 50 10 2 Decommissioning 50 10 3 Disposal 50 11 Declaration of incorporation 51 ...

Page 6: ...he telescope spindle axis service life The illustrations in this manual shall provide you with a basic understanding of the module and may vary from the actual design of your module 1 2 Explanation of symbols The safety notes are marked by a pictogram and a signal word The safety notes describe the extent of the hazard DANGER Danger This safety note indicates an imminently hazardous situation whic...

Page 7: ...risks Warning Dangerous electrical voltage Warning Risk of injury from contact with hot surfaces Warning Risk of hand and finger injury due to uncontrolled movements of components Warning Magnetic field Warning back injury due to heavy lifting Warning Risk of injury as a result of parts being flung out Warning high noise levels 1 3 Additional symbols In these assembly instructions the following sy...

Page 8: ...ctive Afag parts Further claims are excluded The warranty shall expire in the following cases Improper use of the module Non observance of the instructions regarding assembly commissioning operation and maintenance of the module Improper assembly commissioning operation and maintenance Repairs and design changes carried out without prior technical instructions of Afag Automation AG Removing the se...

Page 9: ...rties or in damage to the automation system or other material assets Failure to follow the directions and safety instructions given in this instructions manual may result in serious hazards 2 2 Intended use The telescope spindle axis series SA 3 SA 3 FL und SA 6 SA 6 FL is designed for the shock free linear movement of permanently mounted loads in non explosive environments and in the ambient and ...

Page 10: ...nly personnel who have the necessary professional qualifications and experience are familiar with the basic rules regarding occupational safety and accident prevention have been instructed in the correct handling of the telescope spindle axis have read and understood these assembly instructions The operating company is also required to monitor on an ongoing basis that the personnel work safely con...

Page 11: ...lified personnel may be permitted to carry out the described activities on the telescope spindle axis Persons whose ability to react is restricted due to the intake of medication or the like must not interact with the telescope spindle axis These installation instructions are intended for skilled personnel installers system integrators maintenance personnel technicians electricians and operating p...

Page 12: ... the respective mandatory signs Protective clothing is a close fitting clothing specifically designed to protect personnel from hazards during work Protective gloves are specifically designed to protect the personnel against hand injuries such as cuts abrasion burns Safety shoes are specifically designed to protect the personnel against foot injuries from crushing falling objects or slipping on sl...

Page 13: ...d storage as well as when handling setting up and assembling 2 8 1 General hazards at the workplace The telescope spindle axis has been built according to the state of the art and the applicable health and safety requirements However improper use of the telescope spindle axis may cause the following hazards to the personnel danger to life and limb of the operator or third parties on the telescope ...

Page 14: ... components is required ensure that the work is carried out properly failure to do so will cause serious or fatal injuries Work on the machine s electrical equipment may only be performed by skilled electrician or trained personnel under the supervision of a skilled electrician in accordance with all relevant electrical regulations CAUTION Noise hazards The telescope spindle axis generates 68 dB A...

Page 15: ...abels warning symbols are attached at the following places Check regularly whether the safety labels warning symbols are still present and legible CAUTION Danger of injury from hot surfaces During continuous operation of the telescope spindle axis the surface of the axis heats up Before touching hot surfaces without protective gloves make sure they have cooled down to ambient temperature ...

Page 16: ...nstructions EN SA 3 I SA 3 FL I SA 6 I SA 6 FL Edition 01 2021 Rev 4 5 3 Technical data 3 1 Telescope spindle axis SA 3 and SA 3 FL 3 1 1 Dimension drawing SA 3 and SA 3 FL Fig 1 Dimension drawing telescope spindle axis SA 3 SA 3 FL ...

Page 17: ...Technical data Assembly instructions EN SA 3 I SA 3 FL I SA 6 I SA 6 FL Edition 01 2021 Rev 4 5 17 56 3 1 2 Technical data SA 3 and SA 3 FL ...

Page 18: ...1 2021 Rev 4 5 3 1 3 Preferred combinations SA 3 and SA 3 FL AFAG accepts no liability for the attachment of third party modules to the telescope spindle axis Modules for attachment shall be selected to withstand full load operation of the telescope spindle axis and not exceed the payload ...

Page 19: ...y instructions EN SA 3 I SA 3 FL I SA 6 I SA 6 FL Edition 01 2021 Rev 4 5 19 56 3 2 Telescope spindle axis SA 6 und SA 6 FL 3 2 1 Dimension drawing SA 6 and SA 6 FL Fig 2 Dimension drawing telescope spindle axis SA 6 SA 6 FL ...

Page 20: ...Technical data 20 56 Assembly instructions EN SA 3 I SA 3 FL I SA 6 I SA 6 FL Edition 01 2021 Rev 4 5 3 2 2 Technical data SA 6 and SA 6 FL ...

Page 21: ... Rev 4 5 21 56 3 2 3 Preferred combinations SA 6 and SA 6 FL AFAG accepts no liability for the attachment of third party modules to the telescope spindle axis Modules for attachment shall be selected to withstand full load operation of the telescope spindle axis and not exceed the payload ...

Page 22: ...x and motor must be ordered according to the order key In addition to the assembly and operating instructions a safety information sheet is enclosed with each telescope spindle axis This information sheet must be read by every person who carries out work with and on the telescope spindle axis Unt SA 3 Stck SA 6 1 x Module SA 3 1 x Module SA 6 4 x Centring bushing ø 7x3 2 x Centring bushing ø 7x3 2...

Page 23: ... If the telescope spindle axes are stored for an extended period of time observe the following Store the telescope spindle axis in the transport packaging Do not store the telescope spindle axes outdoors or expose them to weather conditions The storage space must be dry and dust free Room temperature of the storage space 0 50 C Relative air humidity 90 non condensing Clean the telescope spindle ax...

Page 24: ...dvantage to dip into the working area and to leave it again completely The bracket Fig 4 2 is moved along a linear guide Fig 4 3 vis à vis the base body Fig 4 1 A ball type linear drive Fig 4 4 with a spindle nut mounted on the bracket Fig 4 2 transforms the rotary movement in a linear movement The spindle is driven by a servomotor Fig 4 7 via a toothed belt back gear Fig 4 5 or a torsionally stif...

Page 25: ...17754 5 Proximity switch cable R2 3m 90 0 SE 48 50340272 6 Proximity switch cable R2 5m 90 0 SE 48 50340903 7 Encoder cable G5 5m 0 0 SE Power 50075695 8 Encoder cable G6 5m 0 0 SE Power 50100693 9 Encoder cable G8 3m 0 0 SE 48 50341479 10 Encoder cable G8 5m 0 0 SE 48 50341480 11 Encoder cable G9 3m 0 0 SE 48 50341491 12 Encoder cable G9 5m 0 0 SE 48 50341493 13 Motor cable M5 5m 0 open SE Power ...

Page 26: ...stomer must provide an appropriate enclosure or safety barrier No liability for damages can be assumed for damages caused by improper installation assembling work on the part of the operator Also observe the safety instructions in Chapter 2 Safety instructions in this manual CAUTION Risk of injury when installing the telescope spindle axis in a system Improperly performed work can lead to injuries...

Page 27: ...back of the housing The centring sleeves included in the scope of delivery must be used for fastening Chapter 6 2 1 Fig 5 Mounting holes M4 and or M6 on the back of the housing 6 2 2 Tightening torques Use screws with the following minimum specifications for mounting Standard VDI 2230 Screw strength Category 8 8 Surface Galvanized blue oiled or greased Thread Tightening torque M3 1 1 1 4 Nm M4 2 6...

Page 28: ...shings included in the scope of delivery for positioning Insert the centering bushings in two diagonally opposite holes of the attachment grid SA 3 und SA 3 FL Base body Bracket Hole grid 30 x 30 mm 30 x 30 mm Thread Bore M4 M4 Centering bushing H7 Ø 7 mm Ø 7 mm SA 6 und SA 6 FL Base body Bracket Hole grid 48 x 48 mm 30 x 30 mm Thread Bore M6 M4 Centering bushing H7 Ø 9 mm Ø 7 mm ...

Page 29: ...sembly setting Assembly instructions EN SA 3 I SA 3 FL I SA 6 I SA 6 FL Edition 01 2021 Rev 4 5 29 56 6 2 4 Load on the telescope spindle axis SA 3 and SA 6 The following telescope spindle axis loads apply to assembly ...

Page 30: ...Installation assembly setting 30 56 Assembly instructions EN SA 3 I SA 3 FL I SA 6 I SA 6 FL Edition 01 2021 Rev 4 5 6 2 5 Load diagrams SA 3 and SA 6 ...

Page 31: ...ther front left right or axial Fig 6 Possible arrangement of the servomotor 6 3 1 Arrangement options Fig 7 Mounting the motor RIGHT AXIAL 1 Base body 6 Coupling housing 2 Bracket 7 Servo motor 3 Linear guide 8 Holding brake 4 Ball screw axis 9 Motor Encoder connector 5 Toothed belt housing 10 Reference switch connector 10 1 8 4 5 6 7 9 2 3 Motor RIGHT Motor AXIAL ...

Page 32: ...ig 8 3 5 For SA 6 and SA 6 FL Loosen the 4 x screws M5x16 Fig 8 3 6 Rotate the housing Fig 8 4 90 to the left or right swivel 7 For SA 3 and SA 3 FL Tighten 4 x screws Fig 8 3 M4x16 with a tightening torque of 4 Nm 8 For SA 6 and SA 6 FL Tighten 4 x screws Fig 8 3 M5x16 with a tightening torque of 6 Nm 9 Mount and fasten the cover Fig 8 1 10 Reassemble all necessary cables 11 Connect the controlle...

Page 33: ...assignment reference or Emergency Stop switch Pin Signal 1 5 24 V DC 3 GND 4 Signal PNP We recommend using the Afag standard cables specified in the accessories The motor connectors can be rotated 180 Proceed as described below 1 Loosen the screws 2 Rotate the motor connectors 3 Tighten the screws again Fig 9 Adjusting the motor position SA 3 SA 6 Base body A 1 U B 5 V C 2 W D 3 GND Motor 6 Brake ...

Page 34: ...the SA telescope spindle axis type SE 48 Further information on the control units can be found in the technical product catalogue Chapter Controller or in the respective instructions on our website www afag com 6 4 1 SE 48 Controller The plant operator is responsible for the safety of the controller as the telescope spindle axis is controlled by the plant control unit Fig 10 Table of controllers S...

Page 35: ...Installation assembly setting Assembly instructions EN SA 3 I SA 3 FL I SA 6 I SA 6 FL Edition 01 2021 Rev 4 5 35 56 Fig 11 Dimensions Controllers SE 48 ...

Page 36: ...ion assembly setting 36 56 Assembly instructions EN SA 3 I SA 3 FL I SA 6 I SA 6 FL Edition 01 2021 Rev 4 5 6 4 2 SE Power for control cabinet mounting Fig 12 Overview table SE Power for control cabinet mounting ...

Page 37: ...Installation assembly setting Assembly instructions EN SA 3 I SA 3 FL I SA 6 I SA 6 FL Edition 01 2021 Rev 4 5 37 56 Fig 13 Installation SE Power for control cabinet mounting ...

Page 38: ...Installation assembly setting 38 56 Assembly instructions EN SA 3 I SA 3 FL I SA 6 I SA 6 FL Edition 01 2021 Rev 4 5 6 4 3 Servo controller ...

Page 39: ...ontroller unit manufacturer WARNING Risk of injury from unexpected movements and ejected parts due to incorrect programming Incorrect programming can cause uncontrolled movements of the telescope spindle axis resulting in injury and damage to property The telescope spindle axis can also drive into the stop without braking so that people can be injured by ejected parts Have programming carried out ...

Page 40: ...orking on the telescope spindle axis make sure that the control unit is switched off and secured against being switched on again CAUTION Danger of injury in the working area of the telescope spindle axis Due to the decentralised control system the operator of the telescope spindle axis must not necessarily stand next to the module during operation so that he may not have a complete view of the wor...

Page 41: ...rect function of the encoder and the reference switch 6 Perform test run Start with slow movements Then continue under normal operating conditions Commissioning is completed CAUTION Danger due to missing protective devices Operating the telescope spindle axis without suitable safety devices can lead to considerable damage to property and injuries Protective covers safety doors or other safety devi...

Page 42: ...system Observe the operating instructions CAUTION Risk of injury in case of power failure In the event of a power failure during installation and setup work the telescope spindle axis can slide down without a motor brake and injure people The system operator must ensure that no employees are in the danger zone during installation and set up work CAUTION Risk of injury due to mounted components The...

Page 43: ... troubleshooting work can lead to serious injuries and damage to property Only use trained specialist personnel for troubleshooting All work on the telescope spindle axis must be carried out with the power supply cut off NOTICE Danger of material damage due to vibrations on the drive Risk of damage to the telescope spindle axis and attached components if the moving part of the module oscillates ve...

Page 44: ...ope spindle axis does not move Drive incorrectly connected Motor disconnection Drive defective Check terminal assignment and correct if necessary Carry out function check Check motor cable Have the drive replaced by AFAG Malfunction during operation Fault Possible cause Remedy The telescope spindle axis oscillates very strong vibrations at the drive Control parameters incorrectly adjusted Readjust...

Page 45: ...n cause considerable damage to property and serious injury Only use trained specialist personnel to carry out the activities Always wear personal protective equipment when carrying out maintenance and repair work WARNING Risk of injuries due to uncontrolled parts movements When the control system is switched on the telescope spindle axis can make unpredictable movements and cause injury or damage ...

Page 46: ...tenance point Maintenance work Interval System On Off Remarks 1 Safety labels warning symbols check 1 x Month Off Check for damage legibility cleanliness 2 Module Cleaning As required Off With lint free dry cloth Do not spray module with water do not use aggressive cleaning agents 3 Spindle gear Lubricating Every 4 million load cycles Off Recommended lubricant Klüber Microlube GBU Y 131 Alternativ...

Page 47: ...that the control cannot be started up again 3 Remove the blind plug Fig 15 1 from the spindle cover 4 Screw the grease gun attachment see accessories to the grease gun 5 Lubricate the spindle with the grease gun 1 1 5 g Recommended lubricant Klüber Microlube GBU Y 131 Alternative Type KP 1 N DIN 51502 Type NLGI Class 1 DIN 51818 6 Refit the blind plug The lubrication is completed After lubrication...

Page 48: ...ion hole of carriage Procedure for lubricating the linear guide 1 Move the axis to the front end position max stroke 2 Switch off the control and use a lockout device to make sure that the control cannot be started up again 3 Remove grease residues or dirt from the guide rail 4 Lubricate the guideways of the linear guide Fig 16 1 so that an even lubricating film is applied 5 Lubricate the carriage...

Page 49: ... AFAG After the official warranty period has expired wear parts toothed belts can be replaced by the customer The appropriate toothed belts must be ordered from the manufacturer of the telescope spindle axis Other defective module parts may only be replaced by AFAG NOTICE Danger of corrosion damage when used in an ionized air environment When used in an ionized air environment e g coronising in hi...

Page 50: ...e the various components according to type of material and dispose of them properly Scrap the metallic materials Hand over plastic parts for recycling Sort the rest of the components by their material properties and dispose of them accordingly WARNING Risk of injury due to improper decommissioning and disposal Improperly carried out activities can result in considerable material damage and serious...

Page 51: ...1 Harmonised standards applied in particular 2014 30 EU Electromagnetic Compatibility Directive EMC 2014 35 EU Low Voltage Directive LVD EN ISO 12100 2010 Safety of machinery General design principles Risk assessment and risk reduction DIN EN 60204 1 2018 Safety of machinery Electrical equipment of machines Part 1 General requirements Note The partly completed machinery must not be put into servic...

Page 52: ...iations 8 I Instructions 7 O Obligations and liability 10 Obligations of the operating company 10 Obligations of the personnel 11 Operation 43 Operator 11 P Packaging 23 Personal protective equipment PPE 12 Personnel qualifications 11 Personnel requirements 11 Protective clothing 12 Protective gloves 12 Q Qualified electrician 11 Qualified personnel 11 R Residual risks 13 S Safety instructions 9 4...

Page 53: ...M4 on the back of the housing 27 Fig 6 Possible arrangement of the servomotor 31 Fig 7 Mounting the motor RIGHT AXIAL 31 Fig 8 Adjusting the motor position 32 Fig 9 Adjusting the motor position 33 Fig 10 Table of controllers SE 48 34 Fig 11 Dimensions Controllers SE 48 35 Fig 12 Overview table SE Power for control cabinet mounting 36 Fig 13 Installation SE Power for control cabinet mounting 37 Fig...

Page 54: ...54 56 Assembly instructions EN SA 3 I SA 3 FL I SA 6 I SA 6 FL Edition 01 2021 Rev 4 5 ...

Page 55: ...Assembly instructions EN SA 3 I SA 3 FL I SA 6 I SA 6 FL Edition 01 2021 Rev 4 5 55 56 ...

Page 56: ...56 56 Assembly instructions EN SA 3 I SA 3 FL I SA 6 I SA 6 FL Edition 01 2021 Rev 4 5 ...