Afag CR 25 Assembly & Operating Instructions Download Page 9

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General

Assembly instructions EN



CR 25 / CR 32



Edition 01/2020



Rev. 4.0

9–56



Removing the serial number from the product



Using the module without shock absorbers or with defective shock absorbers



Inadequate checking of wear parts



Non-observance of the EC Machinery Directive, the Accident Prevention

Regulations, the Standards of the German Electrotechnology Association

(VDE) and these safety and assembly instructions

1.6 Liability

No changes shall be made to the rotary modules CR 25/CR 32 unless described

in this instructions manual or approved in writing by Afag Automation AG.
Afag Automation AG accepts no liability for unauthorized changes or improper

assembly, installation, commissioning, operation, maintenance or repair work.

Summary of Contents for CR 25

Page 1: ...tions EN CR 25 CR 32 Edition 01 2020 Rev 4 0 1 56 Assembly Operating Instructions Compact Rotary Modules CR 25 CR 32 Translation of the Original Assembly Instructions EN CR 25 Order no 50254300 CR 32 Order no 50254301 ...

Page 2: ... team Subject to modifications The rotary 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 2020 Afag Automation AG All contents of the present assembly and operating instructions in particular the texts photographs and grap...

Page 3: ...el qualification 12 2 6 Personal protective equipment PPE 13 2 7 Changes and modifications 14 2 8 General hazards Residual Risks 14 2 8 1 General hazards at the workplace 14 2 8 2 Danger due to electricity 15 2 8 3 Mechanical hazards 16 2 8 4 Danger due to pneumatics 16 2 8 5 Danger caused by omitting maintenance work 16 3 Technical data 17 3 1 Rotary module CR 25 17 3 1 1 Dimensional drawing CR 2...

Page 4: ...the sensors 38 6 2 5 Mounting of additional modules 39 6 3 Settings 40 6 3 1 Safety notes for settings 40 6 3 2 Adjusting the angle of rotation 41 6 3 3 Setting of the end positions 42 6 3 4 Setting of the end position damping 42 6 3 5 Adjusting the shock absorber 43 7 Commissioning 44 7 1 Safety instructions for commissioning 44 7 2 Commissioning of the modules 44 8 Fault elimination 46 8 1 Gener...

Page 5: ... CR 32 Edition 01 2020 Rev 4 0 5 56 10 Decommissioning disassembly disposal 51 10 1 Safety instructions for decommissioning disassembling and disposal 51 10 2 Decommissioning 51 10 3 Disassembly 51 10 4 Disposal 52 11 Declaration of incorporation 53 ...

Page 6: ...e 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 which if not avoided will result in death or ...

Page 7: ...pplicable the following standardised symbols are used in this manual to point out the various potential health 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 b...

Page 8: ... the rotary module 1 5 Warranty The warranty terms for Afag handling components and handling systems are the following 24 months from initial operation and up to a maximum of 27 months from delivery Wear parts e g shock absorbers are excluded from the warranty The warranty covers the replacement or repair of defective Afag parts Further claims are excluded However a customer has a right to a defec...

Page 9: ...Directive the Accident Prevention Regulations the Standards of the German Electrotechnology Association VDE and these safety and assembly instructions 1 6 Liability No changes shall be made to the rotary modules CR 25 CR 32 unless described in this instructions manual or approved in writing by Afag Automation AG Afag Automation AG accepts no liability for unauthorized changes or improper assembly ...

Page 10: ...ng payloads that do not pose any danger to persons property or the environment during manipulation In combination with other modules the rotary modules can be used as a pick place Station In the chemical industry and in potentially explosive areas the use of rotary modules is not permitted without additional safety measures In such cases please consult with the Afag technical department The intend...

Page 11: ...essary 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 rotary modules have read and understood these assembly instructions The operating company is also required to monitor on an ongoing basis that the personnel work safely considering any potential hazard involved...

Page 12: ...l may be permitted to carry out the described activities on the rotary modules Persons whose ability to react is restricted due to the intake of medication or the like must not interact with the rotary modules These installation instructions are intended for skilled personnel installers system integrators maintenance personnel technicians electricians and operating personnel The following is a des...

Page 13: ...ployer check the personal protective equipment for proper condition and immediately notify the person responsible on site of any defects found on the personal protective equipment Personal protective equipment and the respective mandatory signs Protective clothing is a close fitting clothing specifically designed to protect personnel from hazards during work Protective gloves are specifically desi...

Page 14: ...perating the rotary modules Observe the safety instructions in this chapter and in the other sections of this manual to avoid damage to property and dangerous situations for the personnel 2 8 1 General hazards at the workplace The rotary module has been built according to the state of the art and the applicable health and safety requirements However improper use of the rotary modules may cause the...

Page 15: ... qualified personnel may work with or on the rotary modules Read the assembly instructions carefully before carrying out any work on or with the rotary modules CAUTION Risk of noise induced hearing loss When the rotary modules are installed in a machine or plant the permissible noise level may be exceeded depending on the various components the environment and the resonance The operating company i...

Page 16: ...the system during normal operation Never reach into the system during normal operation WARNING Risks by the pneumatic system The pneumatic system can pose various hazards that can cause serious or fatal injuries if the work is carried out improperly Only qualified personnel may work with or on the pneumatic system The necessary personal protective equipment must be provided and used CAUTION Danger...

Page 17: ...ical data 3 1 Rotary module CR 25 3 1 1 Dimensional drawing CR 25 Type CR 25 P G 1 8 P1 Clockwise P2 Counterclockwise Fig 1 Dimensional drawing Rotary module CR 12 On all modules the hole patterns of the flange are set to 0 position The flange thus turns 100 to the left and 100 to the right ...

Page 18: ...vel 54 dB A Electrical feed through 4 x 1 A Rotary supply fluids 4 Angle accuracy 0 05 Torque 6 2 Nm Max mass moment of inertia observe swivel time diagram 4000 kg cm2 Positions 2 Mounting position Fig 2 Table technical data CR 25 In the end position only half the torque is achieved since in this position the pressure is exerted by one piston only chapter 5 4 The technical data refer to a nominal ...

Page 19: ...tion 01 2020 Rev 4 0 19 56 3 1 1 Preferred combinations CR 25 Note that here might be different mounting positions from one module to another one The required connection elements and the range of support columns are depicted in the catalogue HT Accessories ...

Page 20: ...3 1 2 Module loads CR 25 Type CR 25 Max force axial pushing static 2075 N Max force axial pulling static 800 N Max force axial pushing dynamic 430 N Max force axial pulling dynamic 200 N Max payload radial dynamic 891 N Max payload radial static 3635 N Fig 3 Table module loads CR 25 ...

Page 21: ...Technical data Assembly instructions EN CR 25 CR 32 Edition 01 2020 Rev 4 0 21 56 3 1 3 Load diagrams CR 25 Fig 4 Load diagrams CR 25 ...

Page 22: ... 3 2 Rotary module CR 32 3 2 1 Dimensional drawing CR 32 Type CR 32 P G 1 8 P1 Clockwise P2 Counterclockwise Fig 5 Dimensional drawing Rotary module CR 32 On all modules the hole patterns of the flange are set to 0 position The flange thus turns 100 to the left and 100 to the right ...

Page 23: ...el 54 dB A Electrical feed through 6 x 1 A Rotary supply fluids 4 Angle accuracy 0 05 Torque 13 5 Nm Max mass moment of inertia observe swivel time diagram 10000 kg cm2 Positions 2 Mounting position Fig 6 Table technical data CR 32 In the end position only half the torque is achieved since in this position the pressure is exerted by one piston only chapter 5 4 The technical data refer to a nominal...

Page 24: ...32 Edition 01 2020 Rev 4 0 3 2 3 Preferred combinations CR 32 Note that here might be different mounting positions from one module to another one The required connection elements and the range of support columns are depicted in the catalogue HT Accessories ...

Page 25: ... 2 4 Module loads CR 32 Type CR 32 Max force axial pushing static 2550 N Max force axial pulling static 1600 N Max force axial pushing dynamic 252 N Max force axial pulling dynamic 370 N Max payload radial dynamic 1983 N Max payload radial static 8733 N Fig 7 Table module loads CR 32 ...

Page 26: ...Technical data 26 56 Assembly instructions EN CR 25 CR 32 Edition 01 2020 Rev 4 0 3 2 5 Load diagrams CR 32 Fig 8 Load diagrams CR 32 ...

Page 27: ...ied with an operating and assembly manual and a safety data sheet see scope of supply below Fig 9 Scope of delivery rotary modules CR 25 CR 32 Unt CR 25 Unt CR 32 2 x Center bushing Ø19 x 5 8 mm 2 x Center bushing Ø19 x 5 8 mm 2 x Special screw M10x70 mm 2 x Special screw M10x80 mm 2 x Shock absorber SD M20x1 5 1 2 x Shock absorber SD M25x1 5 1 CAUTION Danger of injury when unpacking the rotary mo...

Page 28: ...wards top side of the package Fragile Products marked with this symbol shall be handled with care and may never be turned upside down or tied up Protect against moisture The packages shall be protected against moisture and kept dry keep covered during storage Attachment points The hosting equipment chain etc may only be attached to the points marked by this symbol Centre of gravity This symbol mar...

Page 29: ...bserve the following Do not store the rotary modules 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 rotary modules and protect the blank metal parts against corrosion using the appropriate means Protect the rotary modules from dirt and dust ...

Page 30: ...Stop sleeve AS 7 Air connection G 1 8 4 Shock absorber SD 8 Fastening holes for mounting devices 5 2 Product description Rotary modules of the CR 25 CR 32 series are precision devices In order ensure safe and reliable operation it is important that the modules are handled with care The rotary modules are highly compact pneumatic modules and are used for the shock free rotation of permanently mount...

Page 31: ...28 5 5 3 2 Other accessories CR 25 CR 32 Shock absorb SD M 20x1 5 1 Shock abs SDM25x1 5 1 Order Number 50252844 Order Number 50252854 Stroke H 15 mm Stroke H 25 mm Net weight 0 07 kg Net weight 0 106 kg Max Energy consumpt stroke 80 Nm Max Energy cons stroke 210 Nm Max Energy consumption h 80 000 Nm Max Energy consumpt h 120 000 Nm Suitable for CR 25 Suitable for CR 32 You will find more informati...

Page 32: ...lace Station However the permissible payloads must not be exceeded Note regarding the torque The specified torque depends on the piston position If a piston is in its end position only half the torque is achieved In this case the pressure is only exerted by the piston which is not in its end position Fig 12 Exerted pressure of the pistons as a function of the piston position Rotation of the module...

Page 33: ... and the compressed air system When connecting the rotary modules to the control unit or the compressed air system sudden unpredictable movements may occur which can cause personal injury or property damage The connecting work may only be carried out by qualified personnel Read carefully the assembly and safety instructions before working with or on the rotary modules CAUTION Danger of injury when...

Page 34: ...ng and hole grid Designation CR 25 CR 32 Hole grid 96 mm 60 mm 48x48mm 96 mm 60 mm Thread Bore screwed trough 2xM10 2xM10 Thread Bore from below 2xM12 2xM8 4xM6 2xM12 2xM8 Centering bushing H7 2xØ19mm 2xØ12mm 2xØ9mm 2xØ19mm 2xØ12mm Order numbers of the special screws Rotary module CR 25 M10x70 mm Rotary module CR 32 M10x80 mm Use the supplied centering bushings to position the rotary modules Inser...

Page 35: ...Installation assembly setting Assembly instructions EN CR 25 CR 32 Edition 01 2020 Rev 4 0 35 56 ...

Page 36: ...d air throttles are closed Vent the system slowly The minimum compressed air quality shall comply with the specifications of ISO 8573 1 2010 WARNING Danger when connecting to pneumatics The pneumatic system can pose various hazards that can cause serious or fatal injuries if the work is carried out improperly Only qualified personnel may work with or on the pneumatic system The necessary personal ...

Page 37: ...connection options for each direction of rotation 1 Upper module half 3 connections G 1 8 clockwise direction of rotation 2 Lower module half 3 Connections G 1 8 counterclockwise direction Fig 14 Pneumatic connection CR 25 CR 32 Fig 15 Pneumatic circuit diagram CR rotary modules 1 Compressed air connection 4 Throttle valve 2 Maintenance unit 5 Rotary module CR 3 4 2 5 2 Way valve 1 1 2 1 2 4 3 5 ...

Page 38: ...nnect the sensor to the control system 3 Carry out a function check on the rotary module and check whether the sensor switches correctly 4 Adjust the position of the rotary module 5 Set the sensor to the desired position 6 Securely fasten the sensor with the fastening screw Fig 16 3 The sensor is mounted Monitoring of the sensors The end position monitoring of the rotary modules is carried out by ...

Page 39: ...or is replaced Fig 17 Magnetic field sensor example illustration 6 2 5 Mounting of additional modules Observe the indicated payloads when mounting additional modules Chapter 3 Technical Data Fig 18 Mounting of additional modules Afag assumes no liability for the integration of modules from other manufacturers on the CR 25 CR 32 rotary modules Make sure that the modules to be integrated are designe...

Page 40: ...he equipment Uncontrolled movements of parts can cause injury to third parties and damage to property Ensure that there are no persons in the working area of the rotary modules CAUTION Danger of injury from uncontrolled restarting of the system equipment Unintentional restarting of the controller or the pneumatic system can cause injuries and material damage When working on the rotary modules make...

Page 41: ... of rotation Maximum rotation angle 200 On all modules the hole patterns of the flange are set to 0 position The flange thus turns 100 to the left and 100 to the right Reduction of the angle of rotation The end positions can be reduced by max 100 starting from the 0 or 200 position 1 Fixation by screwing in the corresponding stop screw If the angle of rotation is reduced by more than 100 a compres...

Page 42: ...ectly adjusted 4 Compressed air at P2 Flange rotates counter clockwise 5 Turn the hexagon of the stop sleeve Fig 20 2 until the desired end position is reached 6 Tighten the clamping of stop sleeves with the clamping screw Fig 20 3 The end positions are set 6 3 4 Setting of the end position damping To adjust the end position damping proceed as follows 1 Loosen the hexagon nut Fig 20 4 on the shock...

Page 43: ...ock absorber make sure that the sealing ring fits exactly against the stop sleeve before tightening the lock nut NOTICE Material damage due to operation without shock absorbers Operation of the rotary modules without shock absorbers leads to mechanical damage and loss of warranty Always operate the rotary modules with shock absorbers NOTICE Material damage due to improper assembly Do not push the ...

Page 44: ... follow the instructions step by step when commissioning the modules for the first time 1 Slowly ventilate the entire system 2 Note the permissible values of the rotary module Chapter 3 for payload movement frequency mechanical stress CAUTION Danger of injury by moving components Limbs can be crushed by moving components Work on and with the rotary modules may only be carried out by qualified pers...

Page 45: ...Edition 01 2020 Rev 4 0 45 56 3 Make sure that there are no persons or tools within the working area of the rotary module 4 Perform test run Start with slow traversing movements then continue under normal operating conditions Commissioning is completed ...

Page 46: ...ted to pneumatics Check connections Check connections End position signal not clear Limit stop incorrectly adjusted Initiator defect Cable break in sensor cable Initiator incorrectly positioned Readjust limit stop Replace initiator Replace initiator cable Position the initiator correctly Module hits the end positions Shock absorber incorrect adjusted Shock absorber defective No shock absorber avai...

Page 47: ...in this manual WARNING Danger of injury due to improper maintenance Improperly carried out maintenance activities can cause considerable damage to property and serious injury The operator must exercise due care and only use trained maintenance personnel to carry out the activities Always wear personal protective equipment when carrying out maintenance and repair work WARNING Risk of injury due to ...

Page 48: ...dule with a dry lint free cloth Do not spray rotary modules with water do not use aggressive cleaning agents Perform a visual inspection of the rotary module 2 Shock absorber Check functioning Monthly Off Check function of shock absorbers replace if necessary 3 Stop screws Check functioning Monthly Off Check function of stop screws replace if necessary 4 Rotary module Check Monthly On Check rotary...

Page 49: ...ypes of oil oil type Festo Special Oil Shell Tellus Oel C 10 Avia Avilub RSL 10 Mobil DTE 21 BP Energol HPL 10 Blaser Blasol 154 Esso Spinesso 10 Oil quantity 5 10 drops of oil per 1000 ltr Compressed air Viscosity range 9 to 11 mm2 s cST at 40 C ISO class VG 10 according to ISO 3448 NOTICE Risk of damage to property Torx type hexagon socket screws may only be loosened by the manufacturer Afag Oth...

Page 50: ...th oil lubricated compressed air causes the factory primary lubrication to be washed out Therefore it is absolutely essential that the rotary modules continue to be operated with oil lubricated compressed air in order to avoid damage to the rotary modules Once the rotary modules have been operated with oil lubricated compressed air they may never be operated without oil lubricated compressed air C...

Page 51: ...nly be dismounted by qualified personnel WARNING Risk of injury due to improper decommissioning disassembly and disposal Improperly carried out activities can result in considerable material damage and serious injury The operator must exercise due care and only use specially trained and qualified personnel for this work CAUTION Risk of injury due to uncontrolled movements of the rotary modules Whe...

Page 52: ...rate 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 NOTICE Risk to the environment due to incorrect disposal of the packaging material Environmental damage can be caused by incorrect disposal of the packag...

Page 53: ... 4 1 1 7 4 2 Harmonised standards applied in particular EN ISO 12100 2010 Safety of machinery General principles for design Risk assessment and risk reduction Note The partly completed machinery must not be put into service until the machinery into which it is to be incorporated has been declared in conformity with the provisions of Machinery Directive 2006 42 EC The manufacturer undertakes to tra...

Page 54: ...nance intervals 48 Maintenance points rotary module 48 Maximum damping effect 43 O Obligations and liability 11 Obligations of the operating company 11 Obligations of the personnel 12 Operator 12 Other accessories 31 P Packaging 28 Personal protective equipment PPE 13 Personnel qualifications 12 Personnel requirements 12 Pneumatic connections Rotary modules 37 Protective clothing 13 Protective glo...

Page 55: ...g 9 Scope of delivery rotary modules CR 25 CR 32 27 Fig 10 Structure of the rotary module CR 30 Fig 11 Initiator INI c10x28 5 31 Fig 12 Exerted pressure of the pistons as a function of the piston position 32 Fig 13 Attachment options rotary modules 34 Fig 14 Pneumatic connection CR 25 CR 32 37 Fig 15 Pneumatic circuit diagram CR rotary modules 37 Fig 16 Illustration of magnetic field sensors 38 Fi...

Page 56: ...56 56 Assembly instructions EN CR 25 CR 32 Edition 01 2020 Rev 4 0 ...

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