Telescope spindle axis SA-1 - Declaration of Incorporation - Module Information - Montage Instructions - Maintenance Instructions Translation of the Original Montage Instructions Copyright by Afag Automation AG
This Montage Instruction a maintenance manual is valid for: Telescope spindle axis SA-1-50/100/150 The actual serial number will be sticked in here upon delivery of the device. Version of the documentation : SA-1-OI-vers.2.3 gb.09.02.15 Symbols : Assembly and commissioning must be carried out by qualified personnel only and according to these Montage Instructions. DANGER Indicates an immediate threatening danger. Non-compliance with this information can result in death or serious personal injuries (invalidity). WARNING Indicates a possible dangerous situation. Non-compliance with this information can result in death or serious personal injuries (invalidity). CAUTION Indicates a possibly dangerous situation. Non-compliance with this information can result in damage to property or light to medium personal injuries. NOTE Indicates general notes, useful operator tips and operating recommendations which don t affect safety and health of the personnel.
Table of contents: 1.0.0 Declaration Incorporation Side 6 1.1.0 Declaration of Incorporation according the Machinery Directive 2006/42/EG Side 6 2.0.0 Module Information Side 7 2.1.0 Transport and storage (packing and unpacking) Side 7 2.1.1 Fastening the module Side 8 2.1.2 Hole spacing and centering bushings Side 9 2.1.3 Tightening torque for screw Side 10 2.1.4 Slide unit load factors Side 11 2.1.5 Module description Side 12 2.1.6 Description module SA-1 Side 13 2.1.7 Description motor arrangement Side 14 2.1.8 Preferred combinations for SA-1 Side 15 2.1.9 Installation for SA spindle axis in a system Side 16 2.2.0 Motor control Interface for spindle axis Side 17 2.2.1 Afag standard controller for spindle axis Side 18 2.2.2 SE-24 Side 19 2.2.3 SE-48 Side 20 2.2.4 SE-Power Side 21 2.2.5 Servo controller Side 22 2.2.6 Programming for the SA spindle extension Side 23 2.2.7 Power fallure during installation and set-up Side 24 2.2.8 Noise emissions Side 25 2.2.9 Protective device at the assembly system Side 25 3.0.0 Montage Instructions Side 26 3.1.1 Manufacturer address Side 26 3.1.2 These operating instructions apply to Side 27 3.1.3 General Description for SA-1 Side 28 3.1.4 Safety note Side 28 3.1.5 Scope of supply/ Intend use/ Safety note Side 29 3.1.6 Warranty Side 30 3.1.7 Dimension for SA-1 Side 31 3.1.8 Technical data Side 32
3.1.9 Installation Side 33 3.2.0 First start-up Side 33 4.0.0 Maintenance Instructions Side 34 4.1.0 Maintenance and service the Telescope spindle axis Side 34 4.1.1 Lubrication of the spindle gear Side 35 4.1.2 Lubrication of the linear guide Side 36 4.1.3 Further maintenance Side 37 4.1.4 Accessories Side 37 4.1.5 Trouble shooting Side 38 4.1.6 Disassembling and repair Side 40 5.0.0 Disposal Side 40 4
1.0.0 EC Declaration for Incorporation (Document original) 1.1.0 According to: 2006/42/EC Standard: EN ISO 12100:2010 (German Version) The manufacturer: Afag Automation AG, Fiechtenstrasse 32, CH-4950 Huttwil hereby declares that the incomplete machine: Producte name: Types : Telescope spindle axis (electrical) SA-1-50 / SA-1-100 / SA-1-150 EC Low voltage Directive: EMC Directive: 2006/95/EC 2004/108/EC Increase of the harmonized EN 60204-1:2006; EN 349 Standard applied: Safety of machinery General principles for risk assessment and risk reduction. The special technical documents shall be sent to a reasoned request by national authorities in printed documents or electronically (pdf). Applied and fulfilled essential requirements: 1.1; 1.1.1; 1.1.2; 1.2; 1.2.1; 1.2.3; 1.2.4.4; 1.2.5; 1.3; 1.3.3; 1.3.5; 1.3.6; 1.3.7; 1.3.8.1; 1.3.8.2; 1.3.9; 1.4; 1.4.1; 1.5; 1.5.1; 1.6; 1.6.1; 1.6.3; 1.6.4; 1.7; 1.7.1; 1.7.4.; 1.7.4.1; 1.7.4.2; 1.7.4.3; 3.3.5; 3.4.1 Who installs this incomplete machine or assemble with other machines, a risk assessment for its resulting machine which must make the provisions of the EC directive: 2006/42 /EC Norme: EN ISO 12100:2010 Agent: For the compilation of the technically relevant documents: Niklaus Röthlisberger, Producte Manager Afag Automation AG, CH-4950 Huttwil Place/Date: Huttwil, 09.02.2015 Siegfried Egli Niklaus Röthlisberger Managing Director Afag Automation AG Producte Manager HT Afag Automation AG
2.0.0 Module Information 2.1.0 Transport and storage (packing and unpacking) CAUTION Caution when to packing and unpacking the telescope spindleaxis! When careless handling of the telescope spindle axis fingers can be pinced as the axis in the state back and forth can be moved! Telescope spindle axis can independently exit The transport takes place in the transport packaging of Afag Automation AG. If there is no packaging of Afag Automation AG are used, they must be the telescope spindle axis shock and dust packed. The axis is in the transport package dry storage. NOTE Depending on the type of SA telescope axis can weight between 0.8 to 1.2 kg. The telescope spindle axis is a fine mechanical unit and must be handled with the necessary care and cleanliness during transport and storage as well as when handling, setting up and assembling. 6
1.1 Fastening the module The module may only be fastened on is underside! SA-1: Hole spacing 30x30 mm / Thread M4 / Centering bushings 7x3 mm Telescope spindle axis: Hole spacing 20x30 mm / Thread M3 / Centering bushings 5x2.5 mm NOTE The threads (M3) on the left and right side of the base body are only used for fastening additional parts (energy chain holder, switch fixtures etc.). View of module under side Telescope spindle axis (X) Modul Un In determining the length of the screws should be noted that the screw of 7 mm is not exceeded. 7
2.1.2 Hole spacing and centering bushings SA-1 Module Braket Hole spacing 30x30 20x30 Thread M4 M3 Use it for positioning the centering bushings supplied. Put them in two diagonally opposite mounting holes of the grid. Centering bushings (H7) Ø 7mm Ø 5mm 8
2.1.3 Tightening torque for screws The screws to be used for assembly must at least satisfy the following conditions: Standard: VDI 2230 Strength: Classe 8.8 Surface: galvanized blue, oiled or greased Thread M3 M4 M5 M6 M8 Torque 1,1 1,4 Nm 2,6 3,3 Nm 5,2 6,5 Nm 9,0... 11,3 Nm 21,6 27,3 Nm Tis is an incomplete machine Assembly of the telescope spindle axis in a system. The series of the telescope spindle axis modules is used for the linear, smooth movement of rigidly mounted loads under the ambient and Installation conditions defined for this module, see Technical data. The Installation position of the telescope spindle axis is arbitrary. NOTE These Montage Instructions should be read carefully before carrying out any activity on or with the telescope spindle axis module. The telescope spindle axis module may only be deployed in accordance with the intended use. 9
2.1.4 Slide unit load factors 10
2.1.5 Module description The following types of the module SA-1are available: Type SA-1-50 SA-1-100 SA-1-150 Nominal stroke 50 mm 100 mm 100 mm Motor attachment optionally on the front left or right side or on the rear axial side. The modules of the SA-series are modules with a movable bracket. Compared with the usual slide model this type series offers the advantage to dip into the working area and to leave it again completely. The bracket (2) is moved along a linear guide (3) vis-à-vis the base body (1). A ball-type linear drive (4) with a spindle nut mounted on the bracket (2) transforms the rotary movement in a linear movement. The spindle is driven by a servomotor (7) via a toothed belt back gear (5) or a torsion ally stiff coupling (6). The reference switch (10) is an inductive sensor which recognizes the home position of the bracket during the reference run. The servomotor (7) can also be equipped with an integrated parking brake (8) which secures the bracket position when the module is not energized. This parking brake is required by all means in case of vertical applications! 11
2.1.6 Description module 1 Base body 6 Coupling housing 2 Bracket 7 Servomotor 3 Linear guide 8 Integrated parking brake 4 Ball screw axis 9 Motor/Encoder connector 5 Toothed belt housing 10 Reference switch connector 12
2.1.7 Description / motor arrangement - Switch off the controller of the module! - Remove cable - Remove cover (1) by unscrewing the screw (2) M3x6 - Remove 4 screws (3) M3x6 - Turn housing (4) by 90 to the left or right - Tighten 4 screws (3) M3x6 with 1.4 Nm - Screw down cover (1) - all Cable mount - Switch on control system CAUTION Carry out a reference run with the module afterwards! (see controller manual) The correct toothed belt tension is retained and must NOT be changed! 13
2.1.8 Preferred combinations for SA-1 NOTE For the cultivation of external modules to the telescope spindle axis over the Afag no liability. Any module are growing so big that they choose for a full telescope spindle axis of the stand and the payload does not exceed. 14
2.1.9 Installation for SA-spindle axis in a system CAUTION Installation of the SA-spindle axis in a system may occur only with switched off and secure control. The Installation of the SAspindle axis may be explained only by a certified professional person. The Installation of the SA-spindle axis may be explained only by a certified professional person. NOTE The investment farmer is himself responsible for the Installation spindle axis in a system. 15
2.2.0 Motor control Interface for telescope spindle axis Pin assignment of the motor connection: Pin assignment of the encoder connection SA-1 Signal A U B V C W D GND Motor + Brake + - Brake - Pin assignment, reference switch connection: Pin SA-1 Signal 1 S1 2 S3 3 S4 4 S2 5 R1 6 R2 7 Thermal switch 8 Thermal switch Pin Signal 1 5... 24 V DC 3 GND 4 Signal, PNP NOTE We recommend you to use the Afag standard cable which are listed in the accessories. Motors plugs can be rotated 180 - Screws solve - Turn the plug - Tighten the screws 16
2.2.1 Afag standard controller for spindle axis NOTE The Afag offers to spindle axis two different controls. You take further information in the technical products catalogue. www.afag.com 17
2.2.2 SE-24 18
2.2.3 SE-48 19
2.2.4 SE-Power 20
2.2.5 Servo controller 21
NOTE Other Controls information Take them in the technical product from catalogue (capter controls). www.afag.com 2.2.6 Programming the SA spindle extension CAUTION Caution: The SA spindle extensions should be started up in setup or jog mode. A wrong programming may trigger uncontrolled movements of the SA spindle extensions. Fast or unintentional movements of the module can result in personal injury and damage to property. The programming depends on the control system used. Observe the respective manuals of the control system supplier. If the Afag SE-Power control system is used, please observe the Montage Instructions which are added to the control system. The Montage Instructions can also be downloaded from the Afag homepage www.afag.com. NOTE If wrong basic data is input at the PLC the SA spindle extension may move unhindered against the stopper leading to injury to persons by parts flying around. In case of a failure of the displacement encoder or a defective limit switch cable the SA spindle extension may execute unexpected movements. Persons working on the system may be injured. CAUTION It is the responsibility of the system manufacturer to ensure that the system is protected with a protective device so that persons are not injured during operation. 22
2.2.7 Power failure during installation and set-up NOTE In case of a power failure the SA spindle extension may glide downward without being braked by the motor so that persons working on the system get injured. CAUTION The person working on the system should therefore never stay under the SA spindle extension. It is the responsibility of the operator to ensure that these measures are observed. Misoperation of the system NOTE During set-up work the SA spindle extension may start due to wrong operation and cause injuries to persons working on the system. CAUTION It is the responsibility of the system manufacturer that persons perform their work properly when adjusting the SA spindle extension so that an uncontrolled start-up of the axis is prevented. Grounding: connection (isolation test in the production process) NOTE The SA spindle extension is to be grounded when it is installed in a system. Carry out an isolation test before start-up. Is it the responsibility of the owner to ensure the safety of the control system which controls the SA spindle extension. 23
2.2.8 Noise emissions NOTE The SA spindle extension generates 68 db(a) during full-load operation. Depending on the add-ons, the environment and the resonance of the protective device these values may be exceeded and result in a disturbing higher noise level. CAUTION It is the responsibility of the system manufacturer to ensure that the permitted noise limit values are complied with. Otherwise an ear protection must be worn if necessary. 2.2.9 Protective device at the assembly system NOTE If an SA spindle extension is mounted in an assembly system the assembly system must be provided with a protective device. Warning: CAUTION Hot surfaces at the motor in continuous operation! 24
3.0.0 Montage Instructions 3.1.0 Manufacturer address: Afag Automation AG Fiechtenstrasse 32 CH-4950 Huttwil Sales Handling: Tel. 0041 (0)62 959 87 02 www.afag.com These Montage Instructions are valid for: Producte name: Typen: Telescope spindle axis (electrical) SA-1-50 SA-1-100 SA-1-150 This is an incomplete machine Who installs this incomplete machine or assemble with other machines, a risk assessment for its resulting machine which must make the provisions of the EC directive: 2006/42/EC Standard: EN ISO 12100:2010 (German Version) Agent: For the compilation of the technically relevant documents: Niklaus Röthlisberger, Products Manager Afag Automation AG, CH-4950 Huttwil 25
3.1.1 These Montage Instructions apply to: Typ: SA-1 Telescope spindle axis: Symbols: Assembly and commissioning must be carried out by qualified personnel only ans according to these Montage Instructions. CAUTION For a potentially dangerous situation, the light body injuries could result. This signal word can also be used for warnings of damage to property may be used. NOTE For potentially harmful situation, where the product or object in its environment may be damaged. 26
3.1.2 General Description for the SA-1 This is an incomplete machine The series of telescope spindle for the telescope spindle axis est arbitraire axis is used for shock-free linear movement of fixed loads in non-hazardous, and in the corridor defined for ambient and operating conditions, see technical data in the current catalog. The mounting position for the telescope spindle axis is arbitrary. 3.1.3 Safety note Note Before any work at with the telescope spindle axis, this Montage Instructions carefully to read. The telescope spindle axis may be used according to the purpose. Modifications on the module that are not described in these Montage Instructions or have not been approved in writing by Afag are not permitted. In case of inexpert changes or improper assembly, installation, operation, maintenance or repairs, Afag rejects all liability. CAUTION The installation of a telescope spindle axis in a system that needs to be protected by one. This could careless people injured. 27
3.1.4 Scope of supply Item 1 2 Qantity Description 1 2 Module Centering bushings Ø 5x2.5 mm 3 2 Centering bushings Ø 7x3 mm Designated Use The series of telescope spindle axis modules SA-3 SA-6 is used for the linear, smooth movement of rigidly mounted loads in non-explosion hazardous ambient and Installation conditions that are specified for this module see Technical Data Sheet. The module can be mounted in any possible position. Safety Instructions These Montage Instructions should be read carefully before carrying out any activity on or with the module. The module may only be used in accordance with the intended purpose. Modifications on the module that are not described in these Montage Instructions or have not been approved in writing by Afag automation are not permitted. In case of inexpert changes or improper assembly, installation, operation, maintenance or repairs, Afag rejects all liability. CAUTION The voltages and currents applied may cause personal injuries and damage to property. 28
3.1.5 Warranty The module is designed for 40 million/2 years* load alterations under the ambient conditions and conditions of deployment defined for this module, see the Technical catalog. Wearing parts (e.g. toothed belts, spindle gears, linear guides) are excluded from this warranty. The warranty includes the repairs or replacement of faulty parts at Afag automation AG. *first go in event Carrying out repairs on the linear guide and the spindle gear without previous instruction by Afag automation AG nullifies the warranty. Any additional claims are excluded. 29
3.1.6 Dimension for SA-1 30
3.1.7 Technical data 31
3.1.8 Installation CAUTION The SA-1 may execute unpredictable movements when the controller is switched on which can cause personal injuries or damage to the system. Make sure that the control system is switched off and secured against being switched on again when working on the module. Disconnect or connect cables only when the control system is switched off. 3.1.9 First start-up CAUTION Fast or unintentional movements of the module can result in personal injury and damage to the unit. Make sure that there are no persons or tools within the operative range of the module. Switch off the control system. Connect the encoder cable. Connect the motor cable. Switch on the control system and check the function of the position sensing system and the reference switch. Carry out a test run - first of all at slow traverse speed, - afterwards under operating conditions. Programming The programming depends on the control system used. Observe the respective manuals. 32
4.0.0 Maintenance instructions 4.1.0 Maintenance and service the telescope spindle axis CAUTION With switched control of the SA-1 can run extra movement and cause injury or property damage. Make sure that the control system is switched off and secured against being switched on again when working on the axis. Maintenance interval Services measures As required Clean the module with a dry, lint-free cloth. The module must not be washed down; do not use any aggressive cleaners. 1 Montly Check the safety labels for damage, readability and cleanliness. Every 4 million load alternations Every 10 million load alternations Lubrication of the spindle drive Recommended grease: Klüber Microlube GBU-Y-131 Optional grease: type KP-1, N (DIN 51502) type NLGI-class 1 (DIN 51818) Lubrication of the linear guide Recommended grease: Klüber STABRAGS NBU 8 EP Optional: Type KP2K NLGI-classe 2 (DIN51818) CAUTION Lubricants with additives such as MoS 2, graphite or PTFE may not be used to service the linear guide. 33
4.1.1 Lubrication of the spindle drive 1 Blind plug 2 Lubrication nipple The spindle gear must be lubricated every 6 million load alternations (strokes). Move axis to the reference position Switch off the control system of the module CAUTION Switch off the control system of the module and secure it against being switched on again unintentionally. The signals of the control system may cause unintentional movements of the module which may lead to personal injuries. Remove the blind plug (1) out of the spindle cover. Regrease the spindle with a grease gun. We recommend to use Klüber Microlube GBU-Y-131 grease. NOTE Instead of the grease mentioned above you may also use a grease of type Typ KP-1, N (DIN 51502) / Typ NLGI-classe 1 (DIN 51818). Fit the blind plug. In order to spread the lubricant evenly 2 3 strokes should be executed at low speed when greasing is completed. 34
4.1.2 Lubrication of the linear guide The linear guide is lubricated with a special long-term grease when shipped. The linear guide must be relubricated every 10 million load alternations (strokes). - Move the axis to the front end position (= max. stroke). - Switch off the control system. - Remove grease residues or dirt from the guide rail. - Grease the tracks of the linear guide (1) in such a way that an even lubricating film is achieved. - Grease the guide carriage with a grease gun (0.2 0.4 g). We recommend to use Klüber STABURAG S NBU 8P grease. In order to spread the lubricant evenly 2 3 strokes should be executed at low speed when greasing is completed. 1 Linear guide tracks 2 Lubricating hole of guide carriage NOTE 35
4.1.3 Further maintenance Under the ambient conditions mentioned below the linear module does not require any further maintenance: clean workshop atmosphere no splash water no dust and fumes caused by abrasion or processes ambient conditions according to the technical catalogue Security sticker At the following places are right security sticker. If they control regularly that security sticker exist and well readable! 4.1.4 Accessories Type Commander SE-24 I/O Commander SE-24 Profibus Commander SE-24 Ether CAT Commander SE-24 CANopen Servomotor-1-24VDC-60W-60-B-I-x-x (to SE-24) Servomotor-1-24VDC-60W-60-x-l-x-x (to SE-24) Encoder cable -G6-5m-0-0 Encoder cable-g8-3m-0-0 (SE-48) Encoder cable-g8-5m-0-0 (SE-48) Encoder cable-g12-3m-0-0 Encoder cable-g12-5m-0-0 Motor cable M10-5m-0-open (SE-Power) Motor cable M11-3m-0-0 (SE-24/48) Motor cable M11-5m-0-0 (SE-24/48) Programming cable (SE-Power, 3m) Proximity switch cable-r8-5m-0-open (SE-Power) Proximity switch cable-r9-5m-0-0 (SE-24) Programming cable (SE-48, 5m) Power cable (SE-24/SE-48, 5m) I/O cable (SE-48, 5m) Centering bushings Ø 5x2.5 Centering bushings Ø 7x3 MSDN für Fett Klüber Microlube GBU-Y-131 Order No. 50315434 see catalog technical 50315435 50315436 50315437 50342862 50342863 50100693 50341479 50341480 50332416 50338975 50219768 50338982 50338983 50038526 50265807 50341478 50103890 50118124 50119231 50035831 11016850 on request 36
4.1.5 Trouble-shooting Faulte during the reference run. CAUTION If the movable part of the module is oscillating heavily after the control system has been switched on (strong vibrations at the drive), switch off the module immediately, since otherwise the unit and the subsystems attached may get damaged. Fault Possible cause Fault clearance Slide oscillates (very strong vibrations at the drive) Slide moves to the retracted limit position and stops Slide moves to the extended limit position and stops Wrong setting of control parameters Wrong connection of limit sensor Limit sensor connection interrupted Limit sensor defective Wrong direction of reference run Reset parameters at the control system Check pin assignment and correct, if necessary Check sensor cable Replace limit sensor according to the repair instructions. Check direction of reference run and change, if necessary Slide does not move Wrong connection of drive Check pin assignment and correct, if necessary Motor connection interrupted Drive defective Carry out functional test according to chapter "First start-up Check motor cable Have the drive replaced by Afag automation AG 37
Faults during operation Fault Possible cause Fault clearance Slide oscillates (very strong vibrations at the drive) Slide stops after a short stroke Toothed belt whistles Spindle whistles excessively Abnormal running noise at the module Wrong setting of control parameters Important contouring error Resolver connection interrupted Reset parameters at the control system Reduce values for acceleration and speed Check whether slide is stalled mechanically Check encoder cable Check encoder for proper functioning. See chapter " First start-up Wrong toothed belt tension Check toothed belt tension and retension according to the repair instructions Toothed belt defective Lubrication of spindle not okay End play in the spindle gear Appreciable play in the slide guide Replace defective toothed belt according to the repair instructions Lubricate spindle Have the spindle gear replaced by Afag AG Have guide replaced by Afag AG 38
4.1.6 Disassembly and repair When the module is damaged it can be returned to Afag AG for repair. CAUTION The module may only be disassembled when the system is aerated and deactivated. If pneumatic connections are disconnected when they are under pressure, this may result in serious personal injury due to fast movements of moving parts. When can the modules be repaired by the customer? Wearing parts can be exchanged by the customer itself when the warranty has expired. NOTE All the other faulty parts must exclusively be replaced by company Afag AG! When the customer detects that the respective module is still under warranty: - He returns the module to company Afag AG for repair. - If the warranty has already expired, the customer must decide whether he repairs the module by himself and orders the wearing parts kit or whether he returns the module to company Afag Automation AG for repair. NOTE Afag offers a reliable repair service. Please note that Afag does not warranty for parts which were not repaired by Afag Automation AG. 5.0.0 Disposal NOTE SA-1 which are of no further use should not be disposed of as a complete unit but dismantled into individual parts according to the type of material and recycled should be correctly disposed of. 39
Afag Automation AG Fiechtenstrasse 32 CH - 4950 Huttwil Schwitzerland Tel.: +41 62 959 86 86 Fax.: +41 62 959 87 87 e-mail: Internet: sales@afag.com www.afag.com