Afag PDL30 Assembly And Operating Instructions Manual Download Page 1

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Assembly instructions



PEL20 I PEL20-SL I PDL30 I PDL40 I PDL40-HP



06.09.2021



Version 4.0 1–68

Assembly and operating instructions

Portal axes

PEL20

PEL20-SL

PDL30

PDL40

PDL40-HP

Translation of the Original Assembly Instructions EN



PEL20



PEL20-SL



PDL30



PDL40



PDL40-HP

Summary of Contents for PDL30

Page 1: ...0 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 1 68 Assembly and operating instructions Portal axes PEL20 I PEL20 SL PDL30 I PDL40 I PDL40 HP Translation of the Original Assembly Instructions EN PEL20 PEL20 SL PDL30 PDL40 PDL40 HP ...

Page 2: ...tate 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 Updates of our documentations Unlike the printed documents our digital instructions manuals product data sheets and catalogues are being continuously updated on our website Please keep in mind that the digital documents on our website are always the l...

Page 3: ...l qualification 11 2 6 Personal protective equipment PPE 12 2 7 Changes and modifications 12 2 8 General hazards residual risks 13 2 8 1 General hazards at the workplace 13 2 8 2 Danger due to electricity 14 2 8 3 Danger due to strong magnetic fields 14 2 8 4 Danger due to high temperatures 14 2 8 5 Mechanical hazards 15 3 Technical data 16 3 1 Portal axis PEL20 SL 16 3 1 1 Dimensional drawing PEL...

Page 4: ...Structure of portal axis 38 5 2 Product description 38 6 Installation assembly and setting 39 6 1 Safety instructions for installation and assembly 39 6 2 Assembly and attachment 40 6 2 1 Mounting material 40 6 2 2 Tightening torques 40 6 3 Connection 41 6 3 1 Power supplies 41 6 3 2 Servo controller 42 6 3 3 Axis controller C11x0 43 6 3 4 Axis controller C12x0 45 6 3 5 Motor connector 47 6 4 Pin ...

Page 5: ... 3 1 Overview of the maintenance points 57 9 3 2 Lubrication of the linear guide 57 9 3 3 Further maintenance 58 9 4 Spare parts lists 58 9 4 1 General 58 9 4 2 Motor overview 58 9 4 3 Spare parts PEL20 PEL20 SL 60 9 4 4 Spare parts PDL30 60 9 4 5 Spare parts PDL40 PDL40 HP 60 9 4 6 Spare parts position measuring system 60 9 4 7 Motor cable 61 9 4 8 Axis controller 61 9 5 Repair and overhaul 62 10...

Page 6: ...l 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 which if not avoided wi...

Page 7: ...ious potential health risks Warning Dangerous electrical voltage Warning Risk of injury from contact with hot surfaces Warning dangerous movements can cause injuries to hands 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 symbols...

Page 8: ...ent or repair of defective 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 Removing...

Page 9: ... 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 electric portal axes are intended exclusively for operation with original LinMot components controller cables in non hazardous atmospheres Any use beyond the described purpose is considered to be not in accorda...

Page 10: ...al axles 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 portal 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 considering any pot...

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

Page 12: ...rsonal 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 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 fa...

Page 13: ...ves property damage Always keep the assembly instructions ready at hand at the workplace Please also observe the general and local regulations on accident prevention and environmental protection the safety information sheet for the portal axis WARNING Danger Do not use in unsuitable environment The portal axes are designed for use in non explosive atmospheres Do not use the portal axis in potentia...

Page 14: ...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 DANGER Danger due to strong magnetic fields Due to the strong magnetic fields electronic devices such ...

Page 15: ...PDL40 HP 06 09 2021 Version 4 0 15 68 2 8 5 Mechanical hazards CAUTION Danger of injury by moving components Limbs can be crushed by moving components Work on and with the portal axis may only be carried out by qualified personnel Never reach into the system during normal operation ...

Page 16: ... 68 Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 3 Technical data 3 1 Portal axis PEL20 SL 3 1 1 Dimensional drawing PEL20 SL Fig 1 Dimensional drawing portal axis PEL20 SL ...

Page 17: ...Technical data Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 17 68 3 1 2 Technical data PEL20 SL ...

Page 18: ...Technical data 18 68 Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 3 1 3 Preferred combinations PEL20 SL ...

Page 19: ...Technical data Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 19 68 3 1 4 Slide loads PEL20 SL ...

Page 20: ...nical data 20 68 Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 3 2 Portal axis PEL20 3 2 1 Dimensional drawing PEL20 Fig 2 Dimensional drawing portal axis PEL20 ...

Page 21: ...Technical data Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 21 68 3 2 2 Technical data PEL20 ...

Page 22: ...Technical data 22 68 Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 3 2 3 Preferred combinations PEL20 ...

Page 23: ...Technical data Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 23 68 3 2 4 Slide loads PEL20 ...

Page 24: ...nical data 24 68 Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 3 3 Portal axis PDL30 3 3 1 Dimensional drawing PDL30 Fig 3 Dimensional drawing portal axis PDL30 ...

Page 25: ...Technical data Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 25 68 3 3 2 Technical data PDL30 ...

Page 26: ...Technical data 26 68 Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 3 3 3 Preferred combinations PDL30 ...

Page 27: ...Technical data Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 27 68 3 3 4 Slide loads PDL30 ...

Page 28: ...nical data 28 68 Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 3 4 Portal axis PDL40 3 4 1 Dimensional drawing PDL40 Fig 4 Dimensional drawing portal axis PDL40 ...

Page 29: ...Technical data Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 29 68 3 4 2 Technical data PDL40 ...

Page 30: ...Technical data 30 68 Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 3 4 3 Preferred combinations PDL40 ...

Page 31: ...Technical data Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 31 68 3 4 4 Slide loads PDL40 ...

Page 32: ... data 32 68 Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 3 5 Portal axis PDL40 HP 3 5 1 Dimensional drawing PDL40 HP Fig 5 Dimensional drawing portal axis PDL40 HP ...

Page 33: ...Technical data Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 33 68 3 5 2 Technical data PDL40 HP ...

Page 34: ...Technical data 34 68 Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 3 5 3 Preferred combinations PDL40 HP ...

Page 35: ...Technical data Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 35 68 3 5 4 Slide loads PDL40 HP ...

Page 36: ...al axis This information sheet must be read by every person who carries out work with and on the module CAUTION Risk of injury when unpacking the portal axes The portal spindle axis can be moved back and forth when it is not fastened causing crushing injuries to the fingers Carefully pack or unpack the portal axis CAUTION Risk of injury when lifting the portal axis Depending on the type the weight...

Page 37: ...4 5 Storage If the portal axis is stored for an extended period observe the following Store the portal axis in the transport packaging in a dry place Do not store the rotational axis outdoors or expose it 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 portal axis and protect the blank ...

Page 38: ...PDL40 1 Portal axis 3 End pieces 2 Slide 4 Linear guide 5 2 Product description The portal axis function according to the slide principle i e the slide moves linearly to a fixed drive unit axis The drive unit flange gear unit and motor is fixed mounted and is therefore not considered part of the moving mass of the system The system consists of an axle the slide of the gear unit and the motor The s...

Page 39: ...the operating company 6 1 Safety instructions for installation and assembly Also observe the safety instructions in chapter 2 Safety instructions in this manual NOTICE Risk of damage due to incorrect installation Incorrect installation can damage the portal axis Only use original LinMot cables for the connection Mount the portal axis only up to an outer dimension of max 600 mm above the end plates...

Page 40: ...ng torque M3 1 1 1 4 Nm M4 2 6 3 3 Nm M5 5 2 6 5 Nm M6 9 0 11 3 Nm M8 21 6 27 3 Nm Module Recommended mounting material PEL20 2x Ø 9h6 centering bushing 4x screw M6 2x Ø 7h6 centering bushing 4x screw M4 2x Ø 5h6 centering bushing 4x screw M3 2x cylindrical pin 5m6 Mounting block for PEL20 PDL30_PDL40 M8 screw PDL30 2x Ø 9h6 centering bushing 4x screw M6 2x Ø 7h6 centering bushing 4x screw M4 2x Ø...

Page 41: ...214 NT01 72 1500Multi Type primary switched power supply primary switched power supply primary switched power supply Primary voltage 90 132VAC 50 60Hz or 180 264VAC 50 60Hz automatic switching 3x340 550 VAC 50 60 Hz 3x230 400 480 VAC 50 60 Hz Secondary voltage 54 80 VDC adjustable 54 80 VDC adjustable 72V DC Output power 480 W 960 W 1500 W Peak output current 0 5 s 10 A 27 A 50 A Efficiency 88 91 ...

Page 42: ...Installation assembly and setting 42 68 Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 6 3 2 Servo controller Fig 10 Overview servo controller ...

Page 43: ...er C11x0 The following is an overview of the controller s interfaces For more information on the C11x0 controller please refer to the data sheet The controllers are pre configured so that as a rule no software adjustments are necessary If adjustments are to be made the software LinMot Talk can be obtained free of charge from the website www linmot com ...

Page 44: ... version X4 8 Quickstop X4 7 Reference sensor optional X4 2 Logic power supply 24VDC X4 1 Logic voltage supply GND DANGER Danger from electric shock when the safety door is open Work on the electrical system carried out unprofessionally can cause serious or fatal injuries Safely disconnect the power supply unit 72V on the primary side at the controller C11x0 or switch off the input Safety Relay X3...

Page 45: ...er C12x0 The following is an overview of the controller s interfaces For more information on the C12x0 controller please refer to the data sheet The controllers are pre configured so that as a rule no software adjustments are necessary If adjustments are to be made the software LinMot Talk can be obtained free of charge from the website www linmot com ...

Page 46: ...ion X4 8 Quickstop X4 7 Reference sensor optional X4 2 Logic power supply 24VDC X4 1 Logic voltage supply GND DANGER Danger from electric shock when the safety door is open Work on the electrical system carried out unprofessionally can cause serious or fatal injuries Safely disconnect the power supply unit 72V on the primary side at the controller C11x0 or switch off the input Safety Relay X33 Net...

Page 47: ...ation connector on axle Combination connector on controller R connector Insert Portal axis PEL20 D connector Insert Controller E11x0 Standard C connector Insert Portal axis PEL30 Portal axis PDL30 Portal axis PDL40 Portal axis PDL40 HP W connector Insert Controller E11x0 Standard HC and XC Controller E12x0 UC Y connector Controller C11x0 XC Controller C1210 XC ...

Page 48: ...our 1 Free 2 Z Blue 3 Z Violet 4 Free 5 5V Brown 6 A Yellow 7 A Red 8 B Green 9 B Orange 10 Free 11 Free 12 GND Black Housing Screen Outer screen 6 4 2 SUB D connector PIN Function Colour 1 5V Pink 2 A sin Yellow 3 B cos Grey 4 Z data White 5 GND Red blue violet 6 Free 7 Free 8 Clock Green 9 A sin Black 10 B cos Red 11 Z Data Blue 12 Free 13 Free 14 Free 15 Clock Grey pink Housing Screen Outer scr...

Page 49: ...the B1100 PP or E1100 GP controller with EasyStep firmware these travel profiles are stored in the controller CAUTION Risk of injuries due to uncontrolled parts movements Incorrect programming can cause the portal axis to make rapid or uncontrolled movements or to drive into the stop without braking and cause serious injuries or damage to property Ensure that the enclosure is closed and that there...

Page 50: ...ble Possibility 3 Set up with safely reduced speed Please observe the associated instructions for safely reduced speed Type Max speed m s Max Accel m s2 Max Delay m s2 Std Speed m s Std Accel m s2 Std Delay m s2 Max Item mm Max Item mm PEL20 080 SL 7 3 120 120 3 15 15 80 0 PEL20 140 SL 7 3 120 120 3 15 15 140 0 PEL20 210 SL 7 3 120 120 3 15 15 210 0 PEL20 270 SL 7 3 120 120 3 15 15 270 0 PEL20 370...

Page 51: ... 15 15 440 0 PDL40 530 D27 3 80 80 2 15 15 530 0 PDL40 70 D28 3 80 80 2 15 15 70 0 PDL40 160 D28 3 80 80 2 15 15 160 0 PDL40 280 D28 3 80 80 2 15 15 280 0 PDL40 370 D28 3 80 80 2 15 15 370 0 PDL40 460 D28 3 80 80 2 15 15 460 0 PDL40 580 D28 3 80 80 2 15 15 580 0 PDL40 670 D28 3 80 80 2 15 15 670 0 PDL40 880 D28 3 80 80 2 15 15 880 0 PDL40 1060 D28 3 80 80 2 15 15 1060 0 PDL40 1270 D28 3 80 80 2 15...

Page 52: ...at when referencing the axis an index is not detected too early or too late This would then lead to a position shift according to the pole pitch of the tape Procedure for setting the distance 1 Configure the system as described in the LinMot controller manual Set the Home Position to 0 mm 2 Reference the axis 3 De energise the axis by removing the switch ON bit 4 Press the axle by hand against the...

Page 53: ...nector PDL30 40 If C motor connector are provided for the PDL30 40 modules the C connector can be rotated in both directions see Fig 14 In this case the maximum rotatability of the C connector must be observed C Connector Fig 14 Setting the C motor connector PDL30 40 modules Our service technicians will be happy to answer any further questions you may have about setting the C motor plugs NOTICE Ri...

Page 54: ...time 1 Switch off the control and use a lockout device to make sure that the control cannot be started up again 2 Connect the encoder cable 3 Connect the motor cable 4 Connect the reference switch cable 5 Switch on the controller unit and check the correct function of the encoder and the reference switch 6 Perform test run Start with slow movements Subsequently under normal operating conditions Co...

Page 55: ...tion correct if nec Carry out function check according to commissioning Check motor cable Have drive replaced by Afag WARNING Danger of injury due to faulty troubleshooting Poorly performed troubleshooting work can lead to serious injuries and damage to property Only use trained specialist personnel for troubleshooting All work on the modules must be carried out with the power supply cut off WARNI...

Page 56: ...ortal axis is to be operated in an environment with abrasive dusts or corrosive or aggressive vapours gases or liquids the approval of Afag must be obtained in advance WARNING Danger of injury due to improper maintenance Improperly carried out maintenance activities can cause considerable damage to property and serious injury Only use trained specialist personnel to carry out the activities Always...

Page 57: ...k As required On Acoustic check for unusual noise development in case of unusual displacement movements or hard knocks eliminate malfunction immediately 3 Guides visual check Every year Off Check for damage 4 Guides and rotor Clean and lubricate Every year Off Chap 9 3 2 Clean guides and rotor with a slightly oily cloth Lubrication of the guides At all lubrication points if necessary press in grea...

Page 58: ...s the order numbers on our delivery note apply Module Stator Rotor Wiper PM20 0130 EL PS01 23x160H HP R PL01 12x420 380 HP PAW01 12 PM20 0190 EL PS01 23x160H HP R PL01 12x480 440 HP PAW01 12 PM20 0290 EL PS01 23x160H HP R PL01 12x580 540 HP PAW01 12 PM20 0470 EL PS01 23x160H HP R PL01 12x760 720 HP PAW01 12 PM20 0560 EL PS01 23x160H HP R PL01 12x850 810 HP PAW01 12 PM20 0140 EL SL PS01 23x80F HP R...

Page 59: ...360 28 PS01 48x240F C PL01 28x710 630 PAW01 28 PDL40 450 28 PS01 48x240F C PL01 28x800 720 PAW01 28 PDL40 570 28 PS01 48x240F C PL01 28x920 840 PAW01 28 PDL40 660 28 PS01 48x240F C PL01 28x1010 930 PAW01 28 PDL40 870 28 PS01 48x240F C PL01 28x1220 1140 PAW01 28 PDL40 1050 28 PS01 48x240F C PL01 28x1400 1320 PAW01 28 PDL40 1260 28 PS01 48x240F C PL01 28x1610 1530 PAW01 28 PDL40 1470 28 PS01 48x240F...

Page 60: ...M30 EL PDL30 PAW01 20 530 227 Grease UH1 14 31 100ml 540 043 Grease gun with Klübersynth UH1 14 31 540 057 9 4 5 Spare parts PDL40 PDL40 HP Designation Article no Motor system stator rotor Motor overview Wiper seal for PDL40 PAW01 28 530 280 Grease UH1 14 31 100ml 540 043 Grease gun with Klübersynth UH1 14 31 540 057 9 4 6 Spare parts position measuring system Designation Article no Magnetic tape ...

Page 61: ... W C 6 080 246 Motor cable 8m EDM2x ES20 SE20 PEL20 carrier Type KS05 D R 8 080 219 Motor cable 8m EDM2x ES20 SE20 PEL20 carrier Type KS05 W R 8 080 244 Motor cable 8m EDM2x ES20 SE20 PEL20 carrier Type KS05 Y R 8 080 687 Motor cable 8m PM25HP 30 ES30 SE30 PDL30 40 carrier Type KS10 W C 8 080 208 Motor cable 8m PM25HP 30 ES30 SE30 PDL30 40 carrier Type KS10 Y C 8 080 695 9 4 8 Axis controller Desi...

Page 62: ...note that Afag does not assume any warranty for modules that have not been replaced or repaired by Afag CAUTION Risk of injuries due to uncontrolled parts movements Risk of injury when removing the portal axis due to uncontrolled movements of the module Only remove the module when the control unit is switched off and secured Only connect or disconnect the cables when the control unit is switched o...

Page 63: ...us 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 injury Onl...

Page 64: ...ive 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 service until the machinery into which it is to be incorporated has been declared in conformity wi...

Page 65: ...abbreviations 8 I Instructions 7 O Obligations and liability 10 Obligations of the operating company 10 Obligations of the personnel 11 Operation 55 Operator 11 P Packaging 37 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 instructio...

Page 66: ...is PDL40 28 Fig 5 Dimensional drawing portal axis PDL40 HP 32 Fig 6 Unpacking the portal axis exemplary representation PDL40 HP 36 Fig 7 Structure of portal axis exemplary representation PDL40 38 Fig 8 Accessories mounting material 40 Fig 9 Overview of power supply units 41 Fig 10 Overview servo controller 42 Fig 11 Axis controller C11x0 44 Fig 12 Axis controller C12x0 46 Fig 13 Distance sensor ta...

Page 67: ...List of figures Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 67 68 ...

Page 68: ...68 68 Assembly instructions EN PEL20 I PEL20 SL I PDL30 I PDL40 I PDL40 HP 06 09 2021 Version 4 0 ...

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