Afag PMP User manual

Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0 1–70
Assembly and operating instructions
Gantry modules
PMP IPMP-c
Translation of the Original Assembly Instructions EN
◼PMP 01 Order no.: 11000105
◼PMP 02 Order no.: 11000106
◼PMP-c 01 Order no.: 11015620
◼PMP-c 02 Order no.: 11015621

2 –70 Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0
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 gantry module or other options.
We wish you every success with our products!
With kind regards
Your Afag team
© Subject to modifications
The gantry 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.
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
latest versions.
© Copyright 2023 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
Luzernstrasse 32
CH-6144 Zell (Switzerland)
Tel.: [phone]
e-mail: [email protected]
Internet: www.afag.com

Table of contents
Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0 3–70
Table of contents
1General....................................................................................................................6
Contents and purpose of these assembly instructions.................................6
Explanation of symbols.................................................................................6
Additional symbols........................................................................................7
Applicable documents ..................................................................................8
Warranty.......................................................................................................8
Liability..........................................................................................................8
2Safety instructions.................................................................................................9
General.........................................................................................................9
Intended use.................................................................................................9
Foreseeable misuse.....................................................................................9
Obligations of the operator and the personnel...........................................10
2.4.1 Observe the assembly instructions......................................................10
2.4.2 Obligations of the operating company..................................................10
2.4.3 Obligations of the personnel ................................................................11
Personnel requirements .............................................................................11
2.5.1 Personnel qualification.........................................................................11
Personal protective equipment (PPE)........................................................12
Changes & Modifications............................................................................12
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 Mechanical hazards .............................................................................14
2.8.4 Danger due to pneumatics...................................................................15
2.8.5 Danger caused by omitting maintenance work....................................15
3Technical data ......................................................................................................16
Gantry module PMP ...................................................................................16
3.1.1 Dimensional drawing PMP...................................................................16
3.1.2 Technical data PMP.............................................................................17
3.1.3 Preferred combinations PMP...............................................................18
3.1.4 Module loads PMP...............................................................................19
3.1.5 Determination of the stroke - PMP.......................................................20
Gantry module PMP-c................................................................................21
3.2.1 Dimensional drawing PMP-c................................................................21
3.2.2 Technical data PMP-c..........................................................................22
3.2.3 Preferred combinations PMP-c............................................................23
3.2.4 Module loads PMP-c............................................................................24
3.2.5 Determination of the stroke - PMP-c....................................................25
4Transport, packaging and storage.....................................................................26

Table of contents
4 –70 Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0
Safety instructions for transport..................................................................26
Scope of supply..........................................................................................27
Transport ....................................................................................................27
Packaging...................................................................................................28
Storage.......................................................................................................28
5Design and description .......................................................................................29
Gantry module PMP version 01 .................................................................31
5.1.1 Structure PMP Version 01....................................................................31
5.1.2 Functional description PMP Version 01...............................................31
Gantry module PMP version 02 .................................................................32
5.2.1 Structure PMP Version 02....................................................................32
5.2.2 Functional description PMP Version 02...............................................32
Gantry module PMP-c version 01 ..............................................................33
5.3.1 Structure PMP-c Version 01.................................................................33
5.3.2 Functional description PMP-c Version 01............................................33
Gantry module PMP-c version 02 ..............................................................34
5.4.1 Structure PMP-c Version 02.................................................................34
5.4.2 Functional description PMP-c Version 02............................................34
Accessories ................................................................................................35
5.5.1 PMP Version 01 ...................................................................................35
5.5.2 PMP Version 02 ...................................................................................36
5.5.3 PMP-c Version 01 ................................................................................37
5.5.4 PMP-c Version 02 ................................................................................38
6Installation, assembly and setting .....................................................................39
Safety Instructions for Installation and assembly.......................................39
Installation and assembly...........................................................................40
6.2.1 Assembly & attachment .......................................................................40
6.2.2 Tightening torques for screws..............................................................41
Setting the PMP/PMP-c modules...............................................................42
6.3.1 PMP/PMP-c Version 01 .......................................................................42
6.3.2 PMP/PMP-c Version 02 .......................................................................43
Connection to the pneumatic system.........................................................44
6.4.1 Pneumatic diagram PMP/PMP-c Version 01 .......................................44
6.4.2 Pneumatic diagram PMP / PMP-c Version 02 .....................................45
Installation of intermediate stops................................................................45
6.5.1 Gantry module PMP.............................................................................45
6.5.2 Gantry module PMP-c..........................................................................46
6.5.3 Installation magnetic switch to intermediate stop.................................46
Adjustment of stop screws (AS 12/60).......................................................47
Adjustment of the shock absorber..............................................................48
6.7.1 Safety notes for settings.......................................................................48
6.7.2 Shock absorber adjustment (SD 14x1-1).............................................49
Installation of the initiator (sensors)............................................................50

Table of contents
Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0 5–70
6.8.1 Proximity switches Ø6.5 mm - for PMP/PMP-c version 01..................51
6.8.2 Initiator Ø6.5 mm Version 02 ...............................................................52
6.8.3 Initiator 8x8 mm....................................................................................53
6.8.4 Option - Initiator for slide control..........................................................54
7Commissioning ....................................................................................................55
Safety instructions for commissioning........................................................55
Commissioning of the modules ..................................................................56
8Fault elimination...................................................................................................57
General Notes ............................................................................................57
Safety instructions for troubleshooting .......................................................57
Table troubleshooting.................................................................................58
9Maintenance and repair.......................................................................................59
General notes.............................................................................................59
Safety instructions for Maintenance and Repair ........................................59
Maintenance activities and maintenance intervals.....................................60
9.3.1 Overview of the maintenance points....................................................60
9.3.2 Lubrication of the ball bearing carriages..............................................61
9.3.3 Compressed air specifications .............................................................63
9.3.4 Further maintenance............................................................................64
Spare and wear parts lists, repairs.............................................................64
9.4.1 General notes.......................................................................................64
9.4.2 Safety instructions................................................................................64
9.4.3 Replace pneumatic cylinder.................................................................65
9.4.4 Replace carriage and guide rail ...........................................................66
10 Decommissioning, disassembly, disposal........................................................67
Safety instructions for decommissioning, disassembling and disposal......67
Decommissioning .......................................................................................67
Disassembly ...............................................................................................67
Disposal......................................................................................................68
11 Declaration of incorporation...............................................................................69

General
6 –70 Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0
1 General
Contents and purpose of these assembly instructions
These assembly instructions contain important information on assembly,
commissioning, functioning and maintenance of the gantry modules PMP and
PMP-c to ensure safe and efficient handling and operation.
Consistent compliance with these assembly instructions will ensure:
▪permanent operational reliability of the module,
▪optimal functioning of the module,
▪timely detection and elimination of defects (thereby reducing maintenance
and repair costs),
▪prolongation of the module 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.
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 ◼PMP I PMPc ◼17.04.2023 ◼V4.0 7–70
This note contains important additional information as well as useful tips for
safe, efficient and trouble-free operation of the gantry 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 - Risk of injury as a result of parts being flung out!
Warning - high noise levels.
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
8 –70 Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0
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 gantry module 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 gantry module.
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 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.
▪Using the compact slide 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.
Liability
No changes shall be made to the gantry module 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
Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0 9–70
2 Safety instructions
General
This chapter provides an overview of all important safety aspects to ensure safe
and proper use of the gantry module and optimal protection of personnel.
Failure to follow the directions and safety instructions given in this instructions
manual may result in serious hazards.
Intended use
The pneumatic gantry modules are used for the linear movement of fixed loads
in non-hazardous atmospheres and in the ambient and operating conditions
defined for this module (technical catalogue).
The gantry modules are only approved for horizontal applications!
The PMP/PMP-c modules are exclusively intended for moving payloads up to a
maximum of 15 kg for the PMP and 5 kg for the PMP-c, which do not react in a
manner that endangers persons, property or the environment when
manipulated.
The gantry modules can be used in combination with other modules as a pick-
and-place station, whereby the permissible load capacity must not be exceeded.
Any use of the gantry module beyond the described purpose is 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.
Foreseeable misuse
Any use other than or beyond the intended use described is considered a
misuse of the gantry modules.
Especially the following use is considered a misuse:
▪Use in potentially explosive atmospheres.
▪Exceeding the permissible payloads.

Safety instructions
10 –70 Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0
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
▪the manufacturer does not accept any liability for damages caused by
improper use.
Obligations of the operator and the personnel
2.4.1 Observe the assembly instructions
A basic prerequisite for safe and proper handling of the gantry module 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 gantry module.
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 gantry module.
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 modules,
▪have read and understood these assembly instructions.
The operating company is also required to:
▪monitor on an ongoing basis that the personnel work safely considering any
potential hazard involved 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,
▪update the related safety data sheets.
WARNING
Risk of injury if the module is not used as intended!
The improper use of the gantry modules poses a potential hazard to the
personnel.
▪The gantry modules may only be used in a technically perfect condition in
accordance with its intended use and the instructions in this manual as well
as in compliance with the safety requirements!
▪Any malfunctions, particularly those that could impair safety, must be
eliminated immediately!