Afag SA-1 Series User manual

Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5 1–52
Assembly and operating instructions
Telescope spindle axis
SA-1 ISA-1-FL
Translation of the Original Assembly Instructions EN
SA-1-050 Order no.: 50249011
SA-1-050-FL Order no.: 50471882
SA-1-100 Order no.: 50249013
SA-1-100-FL Order no.: 50471883
SA-1-150 Order no.: 50249014
SA-1-150-FL Order no.: 50471884

2 – 52 Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5
Dear Customer,
Thank you for choosing our products and placing your trust and confidence in
our company!
These assembly and operating instructions contain all essential information you
need about your product. Our aim is to provide the required information as
concisely and clearly as possible. If, however, you still have any questions on
the contents or suggestions, please do not hesitate to contact us. We are always
grateful for any feedback.
Our team will also be glad to answer any further question you may have
regarding the telescope spindle axis or other options.
We wish you every success with our products!
With kind 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, photographs and graphics, are protected by copyright. All rights reserved.
No part of these assembly and operating instructions may be reproduced,
distributed (made available to third parties), or transmitted in any form or by any
means, including photocopying, recording, or other electronic or mechanical
methods, without the prior written permission of Afag Automation AG.
Afag Automation AG
Fiechtenstrasse 32
CH - 4950 Huttwil (Switzerland)
Tel.: [phone]
Fax.: [phone]
e-mail: [e-mail]
Internet: www.afag.com

Table of contents
Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5 3–52
Table of contents
1General .................................................................................................................... 5
1.1 Contents and purpose of these assembly instructions................................. 5
1.2 Explanation of symbols................................................................................. 5
1.3 Additional symbols........................................................................................ 6
1.4 Applicable documents .................................................................................. 7
1.5 Warranty ....................................................................................................... 7
1.6 Liability.......................................................................................................... 7
2Safety instructions................................................................................................. 8
2.1 General ......................................................................................................... 8
2.2 Intended use ................................................................................................. 8
2.3 Foreseeable misuse ..................................................................................... 8
2.4 Obligations of the operator and the personnel ............................................. 9
2.4.1 Observe the assembly instructions ........................................................ 9
2.4.2 Obligations of the operating company.................................................... 9
2.4.3 Obligations of the personnel ................................................................ 10
2.5 Personnel requirements ............................................................................. 10
2.5.1 Personnel qualification ......................................................................... 10
2.6 Personal protective equipment (PPE) ........................................................ 11
2.7 Changes & modifications............................................................................ 11
2.8 General hazards / residual risks................................................................. 12
2.8.1 General hazards at the workplace ....................................................... 12
2.8.1 Mechanical hazards ............................................................................. 13
2.8.2 Danger due to electricity ...................................................................... 13
2.8.3 Noise hazards ...................................................................................... 13
2.8.4 Danger due to high temperatures ........................................................ 14
2.8.5 Safety labels (warning symbols) .......................................................... 14
3Technical data ...................................................................................................... 15
3.1 Dimension drawing SA-1 and SA-1-FL ...................................................... 15
3.2 Technical data SA-1 and SA-1-FL.............................................................. 16
3.3 Preferred combinations SA-1 and SA-1-FL................................................ 17
4Transport, Packaging and Storage .................................................................... 18
4.1 Safety instructions for transport.................................................................. 18
4.2 Scope of supply .......................................................................................... 18
4.3 Transport .................................................................................................... 19
4.4 Packaging ................................................................................................... 19
4.5 Storage ....................................................................................................... 19
5Structure and description ................................................................................... 20
5.1 Structure telescope spindle axis................................................................. 20
5.2 Product description..................................................................................... 20
5.3 Accessories ................................................................................................ 21

Table of contents
4 – 52 Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5
6Installation, assembly & setting ......................................................................... 22
6.1 Safety Instructions for Installation & Assembly .......................................... 22
6.2 Assembly & attachment.............................................................................. 23
6.2.1 Fastening the module........................................................................... 23
6.2.2 Tightening torques................................................................................ 23
6.2.3 Attachment grid and centering bushings.............................................. 24
6.2.4 Load on the telescope spindle axis ...................................................... 25
6.2.5 Load diagrams...................................................................................... 26
6.3 Motor layout................................................................................................ 27
6.3.1 Arrangement options............................................................................ 27
6.3.2 Adjusting the motor position................................................................. 28
6.3.3 Motor control ........................................................................................ 29
6.4 Afag standard controllers ........................................................................... 30
6.4.1SE-48 Controller................................................................................... 30
6.4.2 SE-Power for control cabinet mounting................................................ 32
6.4.3 Servo controller .................................................................................... 34
6.5 Programming of the telescope spindle axis................................................ 35
6.5.1 Safety instructions for programming .................................................... 35
6.5.2 Programming........................................................................................ 35
7Commissioning .................................................................................................... 36
7.1 Safety instructions for commissioning ........................................................ 36
7.2 Preparatory activities for commissioning.................................................... 37
7.3 Commissioning of the modules .................................................................. 37
7.4 Setting up & retrofitting ............................................................................... 38
8Fault elimination................................................................................................... 39
8.1 Safety instructions for troubleshooting ....................................................... 39
8.2 Fault causes and remedy ........................................................................... 40
9Maintenance and Repair...................................................................................... 41
9.1 General notes ............................................................................................. 41
9.2 Safety instructions for Maintenance and Repair ........................................ 41
9.3 Maintenance activities and maintenance intervals ..................................... 42
9.3.1 Overview of the maintenance points .................................................... 42
9.3.2 Lubrication of spindle gear ................................................................... 43
9.3.3 Lubrication of linear guide .................................................................... 44
9.3.4 Further maintenance ............................................................................ 45
9.4 Spare parts and repair work ....................................................................... 45
10 Decommissioning, disassembly, disposal........................................................ 46
10.1 Safety instructions for decommissioning and disposal............................... 46
10.2 Decommissioning ....................................................................................... 46
10.3 Disposal...................................................................................................... 46
11 Declaration of incorporation............................................................................... 47

General
Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5 5–52
1 General
1.1 Contents and purpose of these assembly instructions
These assembly instructions contain important information on assembly,
commissioning, functioning and maintenance of the telescope spindle axis SA-
1 and SA-1-FL to ensure safe and efficient handling and operation.
Consistent compliance with these assembly instructions will ensure:
permanent operational reliability of the telescope spindle axis,
optimal functioning of the telescope spindle axis,
timely detection and elimination of defects (thereby reducing maintenance
and repair costs),
prolongation of the 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 which, if not
avoided, will result in death or serious injury.
WARNING
Warning!
This safety note points out a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
Caution!
This safety note points out a potentially dangerous situation which, if not
avoided, can result in minor or slight injuries.
NOTICE
This safety note points out a potentially dangerous situation which, if not
avoided, can cause substantial damage to property and the environment.

General
6 – 52 Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5
This note contains important additional information as well as useful tips for
safe, efficient and trouble-free operation of the module.
Further warning signs:
Where applicable, 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 being flung out!
Warning
-high noise levels.
1.3 Additional symbols
In these assembly instructions the following symbols are used to highlight
instructions, results, references, etc..
Symbol Description
1. Instructions (steps ...)
 Results of actions
 References to sections
 Enumerations not ordered

General
Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5 7–52
1.4 Applicable documents
Each telescope spindle axis is accompanied by a safety information sheet.
This information sheet must be read carefully by every person who carries out
work on and with the telescope spindle axis.
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 are excluded from the warranty (The customer is entitled to a
product free of defects. This does also apply to defective accessories and
wear parts. Normal wear and tear are excluded from the warranty.
The warranty covers the replacement 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 Automation AG.
Removing the serial number from the product.
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 telescope spindle axis 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.

Safety instructions
8 – 52 Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5
2 Safety instructions
2.1 General
This chapter provides an overview of all important safety aspects to ensure safe
and proper use of the telescope spindle axis and optimal protection of
personnel.
Safe handling and trouble-free operation of the telescope spindle axis requires
knowledge of the basic safety regulations.
Every person carrying out installation, commissioning, maintenance work or
operating the telescope spindle axis must have read and understood the
complete user manual, especially the chapter on safety instructions.
Beyond this, there are rules and regulations regarding accident prevention that
are applicable to the place of installation which must be observed.
Improper use may result in danger to life and limb of the user or third parties 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-1 and SA-1-FL is designed for the shock-
free linear movement of permanently mounted loads in non-explosive
environments and in the ambient and operating conditions defined for these
modules (technical data sheet in the handling catalogue).
Any use beyond the described purpose is considered to be not in accordance
with the intended use.
The intended use of the module also includes:
observance of all instructions given in this instructions manual,

compliance with the inspection and maintenance work and the
specifications in the data sheets,
using only original spare parts.
2.3 Foreseeable misuse
Any use other than or beyond the intended use described above is considered
a misuse of the telescope spindle axis.
Especially the following use is considered a misuse:
Use in potentially explosive atmospheres

Safety instructions
Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5 9–52
Risks can occur if the module is not used as intended. In the event of
damages caused by improper use the following shall apply:
the operating company shall be solely responsible for such damage, and
Afag does not accept any liability for damages caused by improper use.
2.4 Obligations of the operator and the personnel
2.4.1 Observe the assembly instructions
A basic prerequisite for safe and proper handling of the telescope spindle axis
is a good knowledge of the basic safety instructions.
These assembly instructions, in particular the safety instructions contained
therein, must be observed by all persons working with the telescope spindle
axis.
2.4.2 Obligations of the operating company
In addition to the safety instructions given in this manual, the operating company
must comply with the safety, accident prevention and environmental protection
regulations valid for the field of application of the telescope spindle axis.
The operating company is required to use only 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 considering any
potential hazard involved and the assembly instructions are observed,
ensure that the assembly instructions are always kept at hand at the
installation in which the modules are mounted,
observe and communicate universally applicable laws and regulations
regarding accident prevention and environmental protection,
provide the necessary personal protective equipment (e.g. protective
gloves) and instruct the personnel to wear it.
WARNING
Risk of injury if the module is not used as intended!
The improper use of the telescope spindle axis poses a potential hazard to
the personnel.

The telescope spindle axis may only be used in a technically perfect
condition in accordance with its intended use and the instructions in this
manual and in compliance with the safety requirements!

Any malfunctions, particularly those that could impair safety, must be
eliminated immediately!

Safety instructions
10 – 52 Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5
2.4.3 Obligations of the personnel
All personnel working with the telescope spindle axis are required to:
read and observe these assembly instructions, especially the chapter on
safety,
observe the occupational safety and accident prevention regulations,
observe all safety and warning signs on the telescope spindle axis,
refrain from any activity that might compromise safety and health.
In addition, the personnel must wear the personal protecti
ve equipment
required for carrying out their work. (Chapter 2.6).
2.5 Personnel requirements
2.5.1 Personnel qualification
The activities described in the assembly instructions require specific requisites
at the level of professional qualifications of the personnel.
Personnel not having the required qualification will not be able to assess the
risks that may arise from the use of the telescope spindle axis thus exposing
himself and others to the risk of serious injury. Therefore, only qualified
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 personnel.
The following is a description of the professional skills (qualifications) required
for carrying out the different activities:
Qualified personnel:
Qualified personnel with
appropriate training who are qualified due to their
special know-how and fully familiar with the machine and who have been given
instructions on how to carry out the task entrusted to them safely.
Qualified electrician:
Perso
ns who have obtained their electrical qualifications through appropriate
professional training and complementary courses that enables them to identify
risks and prevent possible hazards resulting from electricity.
Operator (trained personnel):
Authorized persons
who due to their specialized professional training,
expertise and experience are capable of identifying risks and preventing
possible hazards arising from the use of the machine.

Safety instructions
Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5 11–52
2.6 Personal protective equipment (PPE)
The personal protective equipment serves to protect the personnel from hazards
affecting their safety and health at work.
When working on/with the telescope spindle axis, the personnel must wear the
personal protective equipment assigned by the safety officer of the operating
company or as required by safety regulations. In addition, the personnel is
required to:
wear the personal protective equipment provided by the operating company
(employer),
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 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 slippery surfaces.
Hearing protectors
are required to protect the personnel
against excessive noise levels to prevent noise-
induced
hearing loss.
2.7 Changes & modifications
No changes may be made to the telescope spindle axis which have not been
described in these assembly instructions or approved in writing by Afag
Automation AG.
Afag Automation AG accepts no liability for unauthorised changes or improper
assembly, installation, commissioning, maintenance or repair work.
The telescope spindle axis may not be changed or modified in any way,
except with the prior written consent of Afag Automation AG.

Safety instructions
12 – 52 Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5
2.8 General hazards / residual risks
Despite the safe design of the telescope spindle axis and the technical
protective measures taken, there still remain residual risks that cannot be
avoided and which present a non-obvious residual risk when operating the
telescope spindle axis.
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.
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!
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 spindle axis themselves,
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 telescope spindle axis.
WARNING
Danger - Do not use in unsuitable environment!
The telescope spindle axes are designed for use in non explosive
atmospheres.
Do not use the telescope spindle axis in potentially explosive atmospheres!

Safety instructions
Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5 13–52
2.8.1 Mechanical hazards
2.8.2 Danger due to electricity
2.8.3 Noise hazards
CAUTION
Risk of injuries by moving parts and unexpected movements!
When operating the telescope spindle axis uncontrolled movements may
occur which can cause personal injury or property damage. There is always
a risk of injury by moving parts during normal operation.
Only qualified personnel may work with or on the telescope spindle axis.
Never reach into the system during normal operation!
WARNING
Danger! Risk of electric shock!
If work on electrical 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) during full-load operation.
Depending on the add-
ons, the environment and the resonance of the
protective device theses values may be exceeded and expose the operator
to a higher noise level.
It is the responsibility of the operating company to ensure that the permitted
noise limit values are not exceeded.
If the permitted noise levels cannot be met it must be ensured that the
operating personnel wears the required hearing protection.

Safety instructions
14 – 52 Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5
2.8.4 Danger due to high temperatures
2.8.5 Safety labels (warning symbols)
Safety labels (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.

Technical data
Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5 15–52
3 Technical data
3.1 Dimension drawing SA-1 and SA-1-FL
Fig. 1 Dimension drawing telescope spindle axis

Technical data
16 – 52 Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5
3.2 Technical data SA-1 and SA-1-FL

Technical data
Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5 17–52
3.3 Preferred combinations SA-1 and SA-1-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.

Transport, Packaging and Storage
18 – 52 Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5
4 Transport, Packaging and Storage
4.1 Safety instructions for transport
The module can extend independently!
Fig. 2 Telescope spindle axis
Also observe the safety instructions in Chapter 2 „Safety instructions“ in
this manual.
4.2 Scope of supply
The scope of delivery depends on the order of the telescope spindle axis
according to the order key in the technical catalogue or in the website.
Gearbox 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-1 SA-1-FL
1 x Module SA -1 Module SA-1-FL
2 x Centering bushing ø 5x2.5 Centering bushing ø 5x2.5
2 x Centering bushing ø 7x3 Centering bushing ø 7x3
1 x Assembly & operat. instructions Assembly & operating instructions
CAUTION
Risk of injury when unpacking the telescope spindle axis!
The telescope spindle axis can be moved back and forth when it is not
fastened, causing crushing injuries to the fingers.
Carefully pack or unpack the telescope spindle axis.

Transport, Packaging and Storage
Assembly instructions EN SA-1 I SA-1-FL Edition 01/2021Rev. 3.5 19–52
4.3 Transport
No liability can be assumed for damages caused by improper installation on
the part of the operating company.
The following conditions must be complied with for transport and storage:
Storage temperature: 0-50 °C
Relative air humidity: < 90%, non condensing
4.4 Packaging
The telescope spindle axis is transported in the Afag Automation AG transport
packaging. If no Afag packaging is used, the telescope spindle axis must be
packed in such a way that it is protected against shocks and dust.
4.5 Storage
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 axis and protect the blank metal parts against
corrosion using the appropriate means.
Protect the telescope spindle axis from dirt and dust.
NOTICE
Risk to the environment due to incorrect disposal of the packaging
material.
Environmental damage can be caused by incorrect disposal of the packaging
material.
Dispose of the packaging material in an environmentally sensitive way in
accordance with the local environmental regulations.

Structure and description
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5 Structure and description
5.1 Structure telescope spindle axis
Fig. 3 Structure of telescope spindle axis (example)
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
5.2 Product description
The modules of the SA series are telescope spindle axis whose movable part is
designed as 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 (Fig. 3, 2) is moved along a linear guide (Fig. 3, 3) vis-à-vis the
base body (Fig. 3, 1). A ball-type linear drive (Fig. 3, 4) with a spindle nut
mounted on the bracket (Fig. 3, 2) transforms the rotary movement in a linear
movement.
The spindle is driven by a servomotor (Fig. 3, 7) via a toothed belt back gear
(Fig. 3, 5) or a torsionally stiff coupling (Fig. 3, 6). The reference switch (Fig. 3,
10) is an inductive sensor which recognizes the home position of the bracket
during the reference run. The servomotor (Fig. 3, 7) can also be equipped with
an integrated brake system (Fig. 3, 8). The brake secures the bracket position
when the module is not energized.
This brake system is required by all means in case of vertical applications!
10
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8
4
5
6
7
9
2
3