Afag Flipband 200 Product guide

Flexible feed device
Flipband 200 / Flipband 300
Operating and assembly manual
Copyright by Afag GmbH

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This operating manual is valid for:
Type
Order number
Flip conveyor
200
with black conveyor belt
50436249
with white conveyor belt
50436250
Flip conveyor
300
with black conveyor belt
50436251
with white conveyor belt
50436252
Version of this documentation: BA_Flipband_200_300_R03.2_EN.docx
Release: R03.2
Date: 08/07/2018
History
version
changes
R03.0
Documentation of Flipband 200 and Flipband 300
R03.1
Changes of technical data regarding the maximal clockwise belt rotation length
R03.2
Correction of order numbers

R03.2 08/07/2018 Page 3
Contents:
1Safety instructions.............................................................................................5
Explanation of symbols and notices.......................................................................................................... 5
1.1.1 Electrical connection ....................................................................................................................... 6
1.1.2 Danger areas ................................................................................................................................... 7
Proper use ................................................................................................................................................. 7
Obligations of the owner .......................................................................................................................... 8
2Description of the device.................................................................................10
General information ............................................................................................................................... 10
Functional description............................................................................................................................. 10
Technical Data ........................................................................................................................................ 11
Transport ................................................................................................................................................ 12
Assembly of the Unit ............................................................................................................................... 13
2.5.1 Hole pattern for assembly............................................................................................................. 13
2.5.2 Assembly of the 4 holders on the Flipband................................................................................... 14
2.5.3 Assembly of the Flipband on the base plate ................................................................................. 17
Connection of the unit............................................................................................................................. 18
Power supply........................................................................................................................................... 18
Signal designation................................................................................................................................... 19
Cable signal assignment ......................................................................................................................... 20
3Referencing.......................................................................................................21
4Adjustment modes...........................................................................................22
Belt direction, "mode dir" rotary switch ................................................................................................. 22
Belt operating mode, rotary switch "mode rpm".................................................................................... 23
Flip direction, "mode dir" rotary switch .................................................................................................. 24
Flipping operating mode, "mod" rotary switch....................................................................................... 25
4.4.1 Afag test mode .............................................................................................................................. 26
5Control profiles.................................................................................................27
Profiles for belt control ........................................................................................................................... 27
5.1.1 Belt direction and speed via an analog input................................................................................ 27
5.1.2 Belt direction and belt start via a digital input, manual belt speed .............................................. 27
5.1.3 Belt direction and belt start via a digital input, analog belt speed control ................................... 27
Profiles of the flipper control .................................................................................................................. 28
5.2.1 Flipper directions .......................................................................................................................... 28
5.2.2 Profiles of the flipper modes......................................................................................................... 28
6LED displays.....................................................................................................29
7Acknowledge error...........................................................................................30

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8Maintenance instructions ................................................................................31
9Ordering address: ............................................................................................31
10 Disposal ............................................................................................................31

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1 Safety instructions
Explanation of symbols and notices
Symbols: Installation and commissioning must be carried exclusively by qualified
personal according to the operating manual.
Please observe the following explanation of symbols and notices. They are classified
according to danger levels and in according to ISO 3864-2.
DANGER
Identifies an imminently threatening danger.
If the information is not followed, death or severe injuries
(invalidity) can occur.
WARNING
Identifies a potentially dangerous situation.
If the information is not followed, death or severe injuries
(invalidity) can occur.
CAUTION
Identifies a potentially dangerous situation.
If the information is not followed, property damage and
minor or moderate bodily injury can occur.
NOTICE
Identified general information, useful user tips andwork recom-
mendations that have an influence on the safety and health of
the personnel.

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Principle safety information
This operating manual serves as a basis for safe use and operation of the flexible
Flipband feed device. This operating manual, particularly the safety information, must
be observe by all persons working on or with the Flipband. In addition, the rules and
regulations for accident prevention for the respective place of use must be observed.
The operating manual must always be available in the place of use of the Flipband.
Operation of the device must be carried out exclusively by technically qualified person-
nel. Qualified personnel are persons who, on the basis of their training, experience and
instruction, as well as their knowledge of applicable standards, provisions, accident
prevention regulations and operating conditions, have been authorized by the person
responsible for the system of the equipment to carry out the respective necessary
tasks, and are capable of recognizing and avoid the potential dangers in the process
(definition for specialized personnel according to IEC 364).
Faults that can impair the safety of persons, the Flipband or other property must be
corrected immediately.
The following information is provided for personal safety of the operating personnel,
safety of the described products and the connected equipment:
1.1.1 Electrical connection
NOTICE
▪Disconnect the supply voltage before assembly or disassem-
bly work, as well as structural modifications.
▪Observe the accident prevention and safety regulations appli-
cable in the specific usage case.
▪Prior to commissioning, it must be checked whether the rated
voltage of the device matches the local mains supply.
▪EMERGENCY STOP devices must remain valid in all operating
modes. Unlocking the EMERGENCY STOP devices must not
enable uncontrolled restarting.
▪The electrical connections must be exposed!
▪Protective conductor connections must be tested for fault-
free function after assembly!

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1.1.2 Danger areas
NOTICE
The flexible supply devices from Afag are designed in accordance
with the EC Machinery Directive, according to the state-of-the-art
and generally recognized good engineering practices. Neverthe-
less, the use can result in hazards to life and limb of the user or
others and can cause damage to the Flipband or other property.
Proper use
The Flipband is designed for the animation of transported goods, particularly bulk ma-
terial, by means of pulses transferred from flip shafts to the belt. The information in
chapter 2.3 (
Table 1: Technical Data) regarding the maximum permissible dimensions and weights
of conveyor belts must be observed.
The intended use also entails observance of all instructions from the operating man-
ual, as well as the observance of all safety instructions.
WARNING
The Flipband must not be used:
a) in damp and wet areas.
b) at temperatures below 10°C or above 45°C
c) in areas with highly combustible media
d) in areas with explosive media
e) in highly aggressive or dust-laden environments
f) in aggressive environments (e.g.atmospheres contain-
ing salt)

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Obligations of the owner
The Flipband must be in a safe condition and used safely to ensure the safe operation.
Consequently, the operating company is obligated to ensure that the following instruc-
tions are complied with:
Ensure that the Flipband is operated exclusively by authorized personnel.
Forbid unsafe and/or dangerous work procedures. Ensure the appropriate conduct and
actions of personnel.
The personnel must have understood the operating instructions. Have this confirmed
by signature.
Please ensure that a copy of the complete operating instructions is always ready to
hand at the Flipband.
Check the operating manual regularly for completeness and legibility.
For activities with increased risk of injury, stipulate that appropriate personal safety
gear (safety gloves, safety goggles) is worn.
Precisely specify the responsibilities appropriate for the various task areas, such as
installation, commissioning and operation.
Obligate personnel to immediately report recognizable safety deficiencies that occur to
their supervisor.
NOTICE
All persons who work on the Flipband, as well as persons who are
active in accordance with the law on temporary employment bear a
participatory obligation for Occupational Health & Safety. They must
be instructed concerning the use of the Flipband.

R03.2 08/07/2018 Page 9
NOTICE
Reasonably foreseeable misuse, which could pose a danger to the user,
third parties or the Flipband, includes:
a) The feed of components that deviates from the size and geome-
try that deviates specified for the Flipband.
b) Operating the Flipband beyond the physical operating limits as
described in the Chapter “Commissioning/Operation”
c) Improper installation, commissioning and operation of the
Flipband.
d) Modifying the controller software without prior consultation with
the manufacturer
e) Operation of the Flipband with apparent malfunctions and / or de-
fects.
f) Cleaning tasks carried out without observing the local safety pre-
cautions for work on the Flipband.
g) Improper installation, commissioning and operation of the
Flipband.
NOTICE
Not modifications or changes to the Flipband are permitted without
approval of the manufacturer.
NOTICE
Any further use or structural modification applies as improper and
renders the warranty claim void.

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2 Description of the device
General information
The Flipband consists of a conveyor belt and the integrated flip unit, with a control unit
integrated in the flip unit. The control unit is designed for configuration of the possible
operating modes.
The advantages of the Flipband system are:
- Configuration of an individual system, adapted to the respective application
- Fully-integrated embedded system
- Quick and easy parameterization of the modules with controls
- Simple assembly and commissioning
The various types of flexible feed devices differ in size and application spectrum (see
Table 1: Technical Data)
Functional description
The components are transported on the Flipband and separated by means of pulsing.
The loading of components onto the Flipband normally takes place with an electro-
magnetically controlled bunker.
With the movement of the belt, the bulk material is transported to the flip area for puls-
ing. The flip intensity must be adjusted dependingon the component size, weight, char-
acteristics and shape of the bulk material. The valid gripping coordinates are deter-
mined by a camera system in order to feed the separated components to the other
stations with the handling system.
With optimal implementation of the Flipband, the belt transports the accumulated bulk
material to the limit stop (hopper wall) and then to the center position, between the two
flip shafts in order to separate it there. The camera results are used to determine
whether a part can be grabbed, must be flipped again or more parts must be supplied.
In an ideal case, it should be possible to pick up at least one component after each
pulse.
The Flipband can be activated with digital inputs only, as well as analogue and digital
inputs. Depending on the configuration, various parameters can be influences via the
inputs (see 4 Adjustment modes)

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Technical Data
Figure 1: Flip belt dimension sheet
Table 1: Technical Data
Description
Unit
Flipband 200
Flipband 300
Dimensions
A
[mm]
200
300
B
[mm]
220
320
C
[mm]
318
418
D
[mm]
210
310
E
[mm]
~1044
~1044
F
[mm]
154
154
G
[mm]
218
218
H
[mm]
1000
1000
I
[mm]
51
51
J
[mm]
112
112
Max. part size
[mm x mm]
40x40
40x40
Max. part weight
[g]
50
50
Control voltage
[V]
20 –30
20 –30
Load voltage
[V]
9 –30
20 –30
Total current [max]
[A]
7
7
Recommended backup fuse
7A D UL 1p C60N
7A D UL 1p C60N
Relative activation duration of actu-
ators
[%]
< 15%
< 15%
Environmental & / storage tempera-
ture
[°C]
10° –50° / 0° –
80°
10° –50° / 0° –
80°
Weight
[kg]
23
25
Standard interface
Multi I/O
Multi I/O
Protection rating
IP50
IP50
Maximal clockwise belt rotation
length
One full belt rota-
tion
One full belt rota-
tion

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Transport
WARNING
Incorrect use of transport equipment (industrial trucks, hall crane,
aids, slings, etc.) can result in crushing and other injuries. Re-
quired conduct:
▪Observe and adhere to the transport and assembly instruc-
tions
▪Use transport equipment appropriately
CAUTION
The Flipband must only be lifted by the base body for transport.
The hopper is not a lifting point.

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Assembly of the Unit
In order to enable reliable function of the Flipband, the steps below must be followed.
Fault-free operation cannot be guaranteed if it this is disregarded.
2.5.1 Hole pattern for assembly
Figure 2: Hole pattern on assembly level
Description
Flipband 200
Flipband 300
Hole distance X in [mm]
238
338
Hole distance L remains the same for both types

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2.5.2 Assembly of the 4 holders on the Flipband
2.5.2.1 Assembly of the two front holders in the slot of the aluminum profile
Figure 3: Insertion of T-nuts and slotted nuts, of the front holder
Proceed as follows to fasten the 2 holders on the slotted profile:
Slide one of the two accompanying slotted nuts into the upper slot at the desired posi-
tion and secure one of the double T-nuts at the desired position in the lower slot with
a setscrew. (The position depends on your desired L)
This is also repeated on the other side of the Flipband.
NOTICE
The slotted nuts must be installed in the upper slot and the T-nuts
in the lower slot of the aluminum profile.

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Figure 4: Assembly of the two front holders in the slot of the aluminum profile
Now the holder is fastened with the supplied M4x20 (10.9) cylinder head screws and
the corresponding spring washers on the T-block and slotted nut.
NOTICE
Observe the following:
- Maximum torque: 3.5Nm
2.5.2.2 Assembly of the holder for the gear cover
Figure 5: Assembly of the holder for the gear cover
This holder is fastened with the M3x16 (10.9) cylinder head screws and corresponding
spring washers on the side with the holes, facing the belt, below the gear cover.

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NOTICE
Observe the following:
- Maximum torque: 1.8Nm
2.5.2.3 Assembly of the holder opposite the gear cover
Figure 6: Assembly of the holder opposite the gear cover
The last holder is fastened in the same manner as the first two, with M4x20 (10.9) and
the corresponding spring washers.
NOTICE
Observe the following:
- Maximum torque: 3.5Nm

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2.5.3 Assembly of the Flipband on the base plate
Figure 7: Assembly of the Flipband on the base plate
The belt is then mounted with 8 M5 cylinder head screws on the base plate. (These
screws are not included in the scope of supply)
NOTICE
Observe the following:
- Base plate executed as steel plate ≥ 15mm
- Base plate executed as steel plate ≥ 20mm

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Connection of the unit
The actuators of the Flipband are connected by means of the 16-pin socket on the
underside.
Use the supplied connection cable with corresponding plug connector for this purpose.
Figure 8: Connection of the unit
Power supply
WARNING
▪Work on the electrical supply must only be carried
out by trained, approved qualified personnel!
▪The mains supply must be provided by the cus-
tomer via a ground fault circuit breaker!
▪The Flipband must only be operated with the mains
supply specified on the type plate!
The power supply to the Flipband takes place with 24V DC low voltage. The power
supply must be provided by the owner. The manufacturer recommends a 10A slow-
burn melt fuse or a C10A automatic circuit breaker.
Please refer to 2.3 Technical Datafor exact specifications.
Assembly must only be performed by a qualified expert.

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Signal designation
The Sub-D interface of the Flipband has three analogue inputs, four digital inputs and
three digital outputs. The supply voltage is fed via the same supply line. The supply to
the control unit via the control voltage is separate from the supply of the motors via the
load voltage. In the process, the load voltage can be interrupted in case of an emer-
gency stop without making re-referencing necessary.
All signals are listed with the appropriate abbreviations in the following table. These
abbreviations are used in the following text.
Table 2: Signal abbreviation
Abbrevi-
ation
Designation
Description
ULoad
Load voltage
Supply of the motors
ULogic
Control voltage
Supply of the control unit
GND
Ground
UA_Csp
Belt speed
Belt speed analogue input
UD_Cdir
Belt direction
Belt direction digital input
UD_Con
Belt start
Belt start digital input
UA_Fdur
Flip duration
Flip duration analogue input
UA_Fsp
Flip speed
Flip speed analogue input
UD_Fon
Start flipping
Start flipping digital input
UD_AckErr
Acknowledge error
Acknowledge error digital input
UDO_rdy
Stop flipper
Stop flip motors digital output
UDO_err
Error/initialization
Error/initialization active digital output
UDO_run
Ready for operation (run)
Ready for operation digital output (LED run)

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Cable signal assignment
Figure 9: Circuit diagram
Figure 11: Conductor cross-section
Figure 10: Plug pin assignment