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!

Safety instructions
Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0 11–70
2.4.3 Obligations of the personnel
All personnel working with the modules 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 modules,
▪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).
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 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 modules.
Persons whose ability to react is restricted due to the intake of medication or the
like must not interact with the gantry module.
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.
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
12 –70 Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0
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 gantry modules, 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.
Changes & Modifications
No changes may be made to the gantry modules which have not been described
in these assembly instructions or approved in writing Afag Automation AG.
Afag Automation AG accepts no liability for unauthorised changes or improper
assembly, installation, commissioning, maintenance or repair work.
The gantry modules may not be changed or modified in any way, except with
the prior written consent of AFAG.

Safety instructions
Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0 13–70
General hazards / residual risks
Despite the safe design of the machine 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 rotary 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.
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 module.
2.8.1 General hazards at the workplace
The gantry modules have been built according to the state-of-the-art and the
applicable health and safety requirements. However, improper use of the
module may cause the following hazards to the personnel:
▪danger to life and limb of the operator or third parties,
▪on the gantry modules themselves,
▪property damage.
The PMP/PMP-c gantry module 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!
WARNING
Danger - Do not use in unsuitable environment !
The gantry modules are designed for use in non explosive atmospheres.
▪Do not use the gantry module in potentially explosive atmospheres!
CAUTION
Risk of injuries due to uncontrolled parts movements!
When operating the gantry modules uncontrolled movements may occur
which can cause personal injury or property damage.
▪Only qualified personnel may work with or on the module.
▪Read the assembly instructions carefully before carrying out any work on
or with the module.

Safety instructions
14 –70 Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0
2.8.2 Danger due to electricity
2.8.3 Mechanical hazards
CAUTION
Risk of noise-induced hearing loss!
When the gantry modules are installed in a machine or plant, the permissible
noise level may be exceeded depending on the various components, the
environment and the 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.
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.
WARNING
Risk of injury - Do not reach into the system during operation!
There is a risk of injury if the personnel reaches into the system during normal
operation.
▪Never reach into the system during normal operation!
CAUTION
Danger of injury by moving components!
Limbs can be crushed by moving components!
▪Work on and with gantry module may only be carried out by qualified
personnel.

Safety instructions
Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0 15–70
2.8.4 Danger due to pneumatics
2.8.5 Danger caused by omitting maintenance work
WARNING
Risks by the pneumatic system!
The pneumatic system can pose various hazards that can cause serious or
fatal injuries if the work is carried out improperly.
▪Only qualified personnel may work with or on the pneumatic system!
▪The necessary personal protective equipment must be provided and used.
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.

Technical data
16 –70 Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0
3 Technical data
Gantry module PMP
3.1.1 Dimensional drawing PMP
Fig. 1 Dimensional drawing PMP

Technical data
Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0 17–70
3.1.2 Technical data PMP
Fig. 2 Table technical data PMP

Technical data
18 –70 Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0
3.1.3 Preferred combinations PMP

Technical data
Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0 19–70
3.1.4 Module loads PMP
Fig. 3 Table module loads PMP

Technical data
20 –70 Assembly instructions EN ◼PMP I PMPc ◼17.04.2023 ◼V4.0
3.1.5 Determination of the stroke - PMP