Afag LTM-V-100 Quick reference guide

Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0 1-60
Assembly & Operating Instructions
Linear-Transport-Module
LTM-V-100 LTM-V-180
Translation of the Original Assembly Instructions EN
LTM-V-100/180 Order no.: 20190611

2 – 60 Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0
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 Linear-Transport-Module or other options.
We wish you every success with our products!
With kind regards
Your Afag team
© Subject to modifications
The linear transport modules from Afag Automation AG have been built
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 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 LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0 3-60
Table of contents
1General ............................................................................................................... 6
1.1 Contents and purpose of these assembly instructions ............................... 6
1.2 Explanation of symbols ............................................................................. 6
1.3 Additional symbols .................................................................................... 8
1.4 Applicable documents ............................................................................... 8
1.5 Warranty................................................................................................... 8
1.6 Liability ..................................................................................................... 9
2Safety instructions........................................................................................... 10
2.1 General................................................................................................... 10
2.2 Intended use........................................................................................... 10
2.3 Foreseeable misuse................................................................................ 10
2.4 Obligations of the operator and the personnel ......................................... 11
Observe the assembly instructions.................................................... 11
Obligations of the operating company ............................................... 11
Obligations of the personnel.............................................................. 12
2.5 Personnel requirements .......................................................................... 12
Personnel qualification ...................................................................... 12
2.6 Personal protective equipment (PPE)...................................................... 13
2.7 Safety and protection equipment ............................................................. 14
2.8 Changes and modifications ..................................................................... 14
2.9 General hazards / residual risks .............................................................. 15
General hazards at the workplace ..................................................... 15
Danger due to high temperatures...................................................... 16
Danger due to electricity ................................................................... 16
Mechanical hazards .......................................................................... 16
Danger caused by omitting maintenance work .................................. 16
2.10 Safety signs on the LTM or the working environment............................... 17
Warning signs................................................................................... 17
Mandatory signs ............................................................................... 17
3Technical data.................................................................................................. 18
3.1 LTM-V-100-XXXX / LTM-V-180-XXXX .................................................... 18
3.2 Workpiece carrier load ............................................................................ 20
4Transport, packaging and storage .................................................................. 21
4.1 General................................................................................................... 21
4.2 Safety instructions for transport............................................................... 21
4.3 Scope of delivery and accessories .......................................................... 22
4.4 Transport ................................................................................................ 23
4.5 Packaging............................................................................................... 24
4.6 Storage................................................................................................... 24

4 – 60 Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0
5Structure and description................................................................................ 25
5.1 Structure of the linear transport module................................................... 25
5.2 Product description ................................................................................. 26
5.3 Fields of application ................................................................................ 27
6Installation, assembly & setting ...................................................................... 28
6.1 Safety Instructions for installation & assembly ......................................... 28
6.2 Views of the LTM (general view and engine/gearbox installation) ............ 29
6.3 Attachment and tightening torque............................................................ 30
Attachment instructions for LTM........................................................ 30
Tightening torques for screws ........................................................... 31
6.4 Integration of the linear transport module ................................................ 32
Integration of the LTM into an assembly system................................ 32
Integration of the LTM into an assembly system................................ 33
6.5 Gearbox change and motor attachment .................................................. 34
Dismounting of the gear / motor ........................................................ 34
Assembly of the gear / motor ............................................................ 35
6.6 Attachment of external drives.................................................................. 35
6.7 Motor control........................................................................................... 36
6.8 Setting and retrofitting............................................................................. 37
General safety instructions for adjustment and retrofitting work ......... 38
Toothed belt tension ......................................................................... 39
Changing the workpiece carrier......................................................... 40
7Commissioning................................................................................................ 41
7.1 Safety instructions for commissioning...................................................... 41
7.2 Commissioning procedure....................................................................... 42
7.3 Reference run......................................................................................... 42
7.4 Programming .......................................................................................... 43
7.5 Incorrect operation of the system ............................................................ 43
8Fault elimination .............................................................................................. 44
8.1 General Notes ........................................................................................ 44
8.2 Safety instructions for troubleshooting..................................................... 44
8.3 Measures to be taken in the event of faults ............................................. 44
8.4 Tables fault causes and remedy.............................................................. 45
9Maintenance and repair ................................................................................... 47
9.1 General notes ......................................................................................... 47
9.2 Safety instructions for maintenance and repair ........................................ 47
9.3 Maintenance activities and maintenance intervals ................................... 48
Overview maintenance plan .............................................................. 49
Further maintenance......................................................................... 50
9.4 Measures to be taken after maintenance work ........................................ 50
9.5 Repair work ............................................................................................ 50
9.6 spare and wear parts lists ....................................................................... 50
Toothed belt...................................................................................... 51
Side guides....................................................................................... 52

Table of contents
Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0 5-60
10 Decommissioning, disassembly, disposal ..................................................... 53
10.1 Safety instructions for decommissioning, dismantling and disposal.......... 53
10.2 Decommissioning ................................................................................... 53
10.3 Disassembly ........................................................................................... 53
10.4 Disposal.................................................................................................. 54
11 Declaration of incorporation ........................................................................... 55

General
6 – 60 Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0
1 General
1.1 Contents and purpose of these assembly instructions
These assembly instructions contain important information on assembly,
commissioning, functioning and maintenance for a safe and efficient handling of
the Linear-Transport-Module (LTM).
Consistent compliance with these assembly instructions will ensure:
Permanent operational reliability of the linear transport module,
optimal functioning of the linear transport module,
timely detection and elimination of defects (thereby reducing maintenance
and repair costs),
extension of the service life of the linear transport module.
The illustrations in this manual shall provide you with a basic understanding of
the linear transport 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
Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0 7-60
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

General
8 – 60 Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0
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
1.4 Applicable documents
In addition to the assembly instructions, the following documents must be
observed:
Safety data sheets etc.
Instructions for integrated components (supplier documentation).
Each LTM 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 LTM.
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 defect-free product. This does also
apply to defective accessories and wear parts. Normal wear and tear are
excluded from the warranty.
The warranty shall expire in the following cases:
Improper use of the linear transport modules.
Non-observance of the instructions regarding assembly, commissioning,
operation and maintenance of the linear transport modules.
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.

General
Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0 9-60
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 LTM unless described in this instruction
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
10 – 60 Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0
2 Safety instructions
2.1 General
This chapter provides an overview of all important safety aspects to ensure safe
and proper use of the LTM and optimal protection of personnel.
Failure to follow the directions and safety instructions given in this instructions
manual may result in serious hazards.
2.2 Intended use
The linear transport modules of the LTM-V-100 and LTM-V-180 series have
been specially designed for fast workpiece carrier transport and continuous
operation. The linear transport modules are integrated into automation systems.
The linear transport modules series LTM-100-120 and LTM-180-120 are
designed for shock-free, linear transport of permanently mounted workpiece
carriers in non-explosive atmospheres and in the ambient and operating
conditions specifically defined for the respective linear transport module.
In the chemical industry and in potentially explosive areas, the use of LTM is
not permitted without additional safety measures. In such cases, please
consult with the Afag technical department.
The intended use of the module also includes:
Observance of all instructions given in this instruction’s 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
improper use of the linear transport module.
Especially the following use is considered a misuse:
The use for the transport of people and animals.
Use in potentially explosive atmospheres.
Use under conditions with increased dirt content should be avoided, as no
additional protective measures or covers are available.

Safety instructions
Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0 11-60
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 Automation AG does not accept any liability for damages caused by
improper use.
2.4 Obligations of the operator and the personnel
Observe the assembly instructions
A basic prerequisite for safe and proper handling of the LTM 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 LTM.
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 LTM.
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 LTM,
have read and understood these assembly instructions.
The operating company is also required to:
Make sure that the personnel comply with the health and safety requirements
and observes the assembly instructions, ensure that the assembly
instructions are always kept at hand on the machine in which the LTM is
integrated,
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,
update the related safety data sheets.
WARNING
Risk of injury if the module is not used as intended!
The improper use of the LTM poses a potential hazard to the personnel.
The LTM is only to be used in a technically perfect condition in accordance
with the assembly instructions and only for the purpose for which it is
intended!
Any malfunctions, particularly those that could impair
safety, must be
eliminated immediately!

Safety instructions
12 – 60 Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0
Obligations of the personnel
All personnel working with the LTM 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 LTM,
refrain from any activity that might compromise safety and health.
In addition, the personnel must wear the personal protective equipment
required for carrying out their work. (Chapter 2.6).
2.5 Personnel requirements
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 modules 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 LTM.
Persons whose ability to react is restricted due to the intake of medication or the
like must not interact with the LTM.
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:
Persons 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 LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0 13-60
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 LTM, 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 are 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.

Safety instructions
14 – 60 Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0
2.7 Safety and protection equipment
Depending on the application, the LTM must be equipped by the customer with
the safety and protective devices listed below.
Safety device Explanation (example)
Safety barrier with service
doors
When installing the LTM in an assembly system
of the customer, make sure that the substructure
is sufficiently stable! In addition, the customer
must provide a safety barrier with service doors.
Enclosure When the LTM is integrated into an assembly
system, the assembly system must be provided
with an enclosure, since high acceleration and
deceleration values can occur when the system
is running at full capacity.
Persons may be injured by flying parts ejected
from the LTM.
Cleaning station Parts lying around on the workpiece carriers can
get into the LTM and cause malfunctions or failure
of the system.
To avoid this, a suitable cleaning station must be
provided.
2.8 Changes and modifications
No changes may be made to the LTM 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 LTM may not be changed or modified in any way, except with the prior
written consent of Afag Automation AG.
WARNING
Danger of injury for the personnel!
Danger of injuries resulting from improperly mounted or inoperable safety and
protective devices!
The LTM may only be put into operation with completely mounted and fully
functional safety and protective devices.
Never remove or disable safety or protective devices!

Safety instructions
Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0 15-60
2.9 General hazards / residual risks
Despite the safe design of the LTM 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 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.
General hazards at the workplace
The LTM has been built according to the state-of-the-art and the applicable
health and safety requirements. However, improper use of the LTM may expose
the personnel to the following hazards:
Danger to life and limb of the operator or third parties,
on the LTM itself,
property damage.
Always keep the assembly instructions ready at hand at the workplace!
Please, also observe:
T
he general and local regulations on accident prevention and
environmental protection.
The safety information sheet for the LTM.
CAUTION
Danger of excessive strain when lifting too heavy objects!
Lifting heavy parts may result in excessive strain and injury.
When lifting loads heavier than 15 kg use two people or suitable lifting
equipment.
CAUTION
Risk of noise-induced hearing loss!
The LTM generates < 70 dB(A) at full load. These decibel levels can be higher
depending on the attachments, the environment and the enclosure
resonance.
The operating company is responsible for ensuring that the permissible
noise levels are observed.
If the noise level exceeds 85 dB(A) in normal operation, the operator must
wear hearing protectors at the workplace.

Safety instructions
16 – 60 Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0
Danger due to high temperatures
Danger due to electricity
Mechanical hazards
Danger caused by omitting maintenance work
WARNING
Danger of injury from hot surfaces.
During continuous operation of the LTM, the surface of the drive motor heats
up (up to 100°C).
Before touching hot surfaces without protective gloves, make sure they
have cooled down to ambient temperature.
WARNING
Danger! Risk of electric shock!
Work on the electrical system carried out unprofessionally can cause serious
or fatal injuries.
Work on the machine's electrical equipment may only be performed by
skilled electrician or properly trained personnel under the supervision of a
skilled electrician in accordance with all relevant electrical regulations.
CAUTION
Risk of injury in the area of the deflection of the LTM!
Risk of crushing injuries to the fingers and hands, especially at the deflector
and drive modules!
There must be no persons or loose tools in the working area of the LTM.
CAUTION
Danger of injury!
Poor or not regularly performed maintenance work may cause malfunction of
the components which may result in injuries.
The due diligence obligations of the operating company include ensuring
that the personnel carrying out maintenance work is appropriately trained
and qualified.

Safety instructions
Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0 17-60
2.10 Safety signs on the LTM or the working environment
The following symbols and warning signs are attached to the LTM or the working
environment depending on the machine type and working process.
Keep all warning signs (e.g. safety and danger information) on the LTM or
working environment complete and legible. Replace any illegible warning
signs or tags immediately.
Warning signs
Warning
- Dangerous electrical voltage.
Warning
- Risk of injury from contact with hot surfaces.
Warning
-
Risk of hand and finger injuries due to uncontrolled
movements of components.
Mandatory signs
Observe assembly instructions and other applicable documents!
Switch off before
starting maintenance or repair work!

Technical data
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3 Technical data
3.1 LTM-V-100-XXXX / LTM-V-180-XXXX
LTM-V
Speed up to 180 cycles/min
Repeatability +/- 0.1 mm
Feed lengths
10, 20, 30, 40, 60, 80, 90, 120, 180, 240 mm or continuous operation
Feed time From 0.1 sec. depending on feed length and workpiece carrier load
Hole pattern workpiece
carrier attachment
Individually according to customer requirements
Type LTM-V-100-XXXX LTM-V-180-XXXX
Working length L1 without middle module 720 mm 720 mm
Working length / middle module 600 mm 600 mm
Max. Working length 3720 mm 3720 mm
Max. number of middle modules
5
5
Number of workpiece carrier without middle module
6
6
Additional workpiece carrier/middle module 5 5
Workpiece carrier length 120 mm 120 mm
Workpiece carrier width A 100 mm 180 mm
Workpiece carrier height 12 mm 12 mm
Max. usable workpiece carrier surface 80 x 118 mm 160 x 118 mm
Max. workpiece carrier nest height
80 mm
80 mm
Max. payload / workpiece carrier up to 3 kg depending on total length

Technical data
Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0 19-60
Max. no. of middle modules 0 1 2 3 4 5
Workpiece carrier total 20 30 40 50 60 70
Total workstations (L1) 6 11 16 21 26 31
Total length L [mm] 1180 1780 2380 2980 3580 4180
Usable length L1* [mm] 720 1320 1920 2520 3120 3720
* Use length value to which the elongation factor 1.00135 must be applied.
Dimension of workp. carrier [mm] [mm]
A 100 180
B 118 118
C 142 222
Bw 82 162
H 305 305
Hw 300 300
Middle modules
Running direction
Max. carrier attachm. size

Technical data
20 – 60 Assembly instructions EN LTM-V-100 / LTM-V-180 Edition 03/2020 Rev. 2.0
3.2 Workpiece carrier load
Type LTM-V-100 LTM-V-180
Max Moment Mx 50 Nm 50 Nm
Max Moment My 50 Nm 50 Nm
Max Moment Mz 100 Nm 100 Nm
Max forces Fx 100 N 100 N
Max forces Fy
500 N
500 N
Max forces Fz 5000 N 5000 N