Afag RE Series User manual

Electric Rotary Module
RE-50 I RE-75
Declaration of Incorporation
Module Information
Montage Instructions
Maintenance Instructions
„Translation” of the original Montage Instructions
© Copyright by Afag Automation AG

2RE-50-RE-75-OI-vers. 2.6 gb 28.07.14
This Montage Instructions applies to:
Type
Order No.
RE-50
RE-75
RE-50 24V/48V
RE-75 48V
50285554
50285555
50328767
50332293
Version of this doc-
umentation:
RE-50-RE-75-OI-vers. 2.6 gb 28.07.14
Symbols: Assembly and initial start-up must be carried out by qualified personnel
only and according to these Montage Instructions.
DANGER
Indicates an immediate threatening danger.
Non-compliance with this information can result in death or se-
rious personal injuries (invalidity).
WARNING
Indicates a possible dangerous situation.
Non-compliance with this information can result in death or se-
rious personal injuries (invalidity).
CAUTION
Indicates a possibly dangerous situation.
Non-compliance with this information can result in damage to
property or light to medium personal injuries.
NOTE
Indicates general notes, useful operator tips and operating recom-
mendations which don't affect safety and health of the personnel.

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Table of Contents:
1.0.0 EC Declaration for Incorporation ...................................................................5
2.0.0 Module Information..........................................................................................7
2.1.0 Safety.............................................................................................................7
2.1.1 Transport, Handling, Storage .........................................................................7
2.1.2 Module Description.........................................................................................7
Module designation........................................................................................ 8
2.1.3 Mounting, Connection.....................................................................................8
Tightening moments for screw......................................................................10
2.1.4 Installation in a system.................................................................................10
2.1.5 Preferred combinations to RE-50 .................................................................12
2.1.6 Preferred combinations to RE-75 .................................................................13
3.0.0 Montage Instructions .....................................................................................14
3.1.1 Scope of delivery..........................................................................................15
3.1.2 Intended use.................................................................................................15
3.1.3 Warranty.......................................................................................................16
3.1.4 Safety...........................................................................................................16
3.1.5 Dimension drawing RE-50 / RE-75..............................................................17
3.1.6 Technical data..............................................................................................18
3.1.7 Rotary module electrical ( without flange).....................................................19
3.1.8 Flange rotation.............................................................................................20
3.1.9 Measured values with...................................................................................22
3.2.0 Installation of external modules....................................................................22
3.2.1 Electrical interfaces ......................................................................................23
Motor cable..................................................................................................23
Encoder cable..............................................................................................23
3.1.2 Commissioning, Operation, Training ............................................................24
3.1.3 Preparation for commissioning.....................................................................25
3.1.4 Commissioning.............................................................................................26
Training....................................................................................................... 26
3.1.5 Setting, Changing.........................................................................................26

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3.1.6 Normal operation..........................................................................................27
4.0.0 Maintenance Instruction.............................................................................28
4.1.0 Maintenance and servicing...........................................................................28
4.1.1 Regular maintenance ...................................................................................29
Additional maintenance ...............................................................................29
4.1.2 Hot surface during operation........................................................................29
4.1.3 Troubleshooting and repair...........................................................................29
4.1.4 Possible failures ...........................................................................................30
4.1.5 End position sensor replacement .................................................................31
4.1.6 Repair...........................................................................................................31
4.1.7 Accessories..................................................................................................32
4.1.8 Disassembly and repair................................................................................33
5Disposal.......................................................................................................33
6Annexe.........................................................................................................34
6.0.0 List of Figures...............................................................................................34
6.1.0 List of Tables................................................................................................34

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1.0.0 EC Declaration for Incorporation
1.1.0 According to 2006/42/EC dated 09. June 2006, Appendix II B VI for
Incorporation of partly completed machinery.
The manufacturer: Afag Automation AG, Fiechtenstrasse 32, CH-4950 Huttwil
Tel. [phone], www.afag.com
As manufacturer of the partly completed machine we declare that:
-The specified machine corresponds to the listed essential requirements of the
directive 2006/42/EG, wehere applicable the other directives and standards
listed below.
Producte name:
Rotary modules electrical
Types:
RE-50 / RE-75
RE-50 24V/48V
RE-75 48V
Sequential series:
The actual serial number will
be sticked in here upon delivery
of the device.
-Machinery Directive 2006/42/EC
-Low voltage Directive 2006/42/EG
-EMV-Guideline 2004/108/EG
-EG Production Safety Directive 2001/95/EG
-EG RoHS 2002/95/EG
-The relevant technical documentation is compiled in accordance with part B of Annex
VI
-The relevant technical documentation in accordance with part B of Annex VI will be
transmitted in response to a reasonable request by the national authorities in printed
from or in electronic from (pdf).
-
Notes to the Declaration of Incorporation according to the Machinery Directive
2006/42/EC, Annex IIB, section 4.
(Checklist on accurate and basic health and safety requirements).
-1.1; 1.1.1; 1.1.2; 1.2; 1.2.1; 1.2.3; 1.2.4.4; 1.2.5; 1.3; 1.3.3; 1.3.5; 1.3.6; 1.3.7; 1.3.8.1;
1.3.8.2; 1.3.9; 1.4; 1.4.1; 1.5; 1.5.1; 1.6; 1.6.1; 1.6.3; 1.6.4; 1.7; 1.7.1; 1.7.4.; 1.7.4.1;
1.7.4.2; 1.7.4.3; 3.3.5; 3.4.1
-Increase of the harmonized standards applied:
-EN 349; EN ISO 12100-1; EN 12100-2; EN ISO 14121-1; EN 60204-1: 2006 partly
fulfilled

6RE-50-RE-75-OI-vers. 2.6 gb 28.07.14
This partly completed machinery must not be put into service until the final machinery
into which it is to be incorporated has been declared in conformity with the provisions
of this Directive 2006/42/EC, where appropriate.
Name and address of the person authorised to compile the relevant technical documentation:
Lanz Beat, PM & Marketing-Services, Afag Automation AG
Place/Date: Huttwil, 28.07.2014
Markus Werro
Managing Director
Afag Automation AG
Siegfried Egli
Head of HT
Afag Automation AG

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2.0.0 Module Information
2.1.0 Safety
Modifications to the RE rotary module that are not described in this Montage Instruc-
tions or have not been approved in writing by the company Afag Automation AG are
not permitted. In case of improper changes or assembly, installation, operation,
maintenance or repair, Afag Automation AG rejects all liability.
2.1.1 Transport, Handling, Storage
For transport and storage, the following must be met:
Temperature storage: 0-50°C
Humidity: <90%, non condensing
CAUTION
The RE rotary module is packed in the original box. In the case of
improper handling the module may drop out of the box when it is un-
packed and cause injuries to limbs.
The RE rotary module has weight of less than 1 kg (RE-50) or less than 2 kg (RE-75)
respectively.
NOTE
Please note:
A technical safety information sheet is enclosed with each module.
This information sheet must be read by every person who operates
the module.
2.1.2 Module Description
The RE rotary module is a very compact electrical rotary module which is suitable for
rotating useful loads (see Technical Data). The RE rotary modules are fitted with a
17-pole industrial connector (G13) and a 4-pole M15 connector.
The RE rotary module is designed for being operated with the Afag SE-24 control
system. It can also be operated with other controller types.
Further technical details can be found in section 3.5 of this manual.

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Module designation
1 Servo-drive with gearing
2 Encoder casing
3 Rotary flange
4 Encoder connection
5 Proximity switch
6 Motor connection
7 Mounting holes on the rear (see dimensions drawing)
Figure 1: Module designation
The RE rotary module consists of the servo-drive with gearing (1) with integrated
electric motor.
2.1.3 Mounting, Connection
WARNING
Due to the rotating movement of the rotary flange garments,
hair or other materials may be caught and drawn into the sys-
tem while the module is being operated.
Caution: Commissioning may only be executed by qualified
personnel.
1
2
3
4
5
7
6

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WARNING
Due to the decentral controller the operator of the RE rotary
module needs not to be near the product so that third persons
might be endangered by the rotation mode.
Always switch off the controller and protect it from being
switched on again unintentionally when you work on the RE
rotary module. The signals of the control system can cause un-
intentional movements of the module which may lead to per-
sonal injuries.
The RE-50 / RE-75 rotary modules can be installed in a vertical and horizontal posi-
tion.
The RE-50 / RE-75 rotary modules are fastened at the rear of the housing. The RE-
50 is fitted in the 30 x 30mm hole matrix with 4 M4 bolts (bolt circle 58 mm, through-
hole 4 x 3.4 mm) while the RE-75 module is fitted in the 48 x 48 mm hole matrix with
4 M5 bolts (bolt circle 88 mm, through-hole 4 x 5.5 mm).
The corresponding connection plates must be used for mounting the Afag modules.
Figure 2: Installation and mounting options
Use the centering bushings included in the scope of supply for positioning and insert
these sleeves in the diagonally opposite bore holes of the mounting grid.
RE-75
RE-50
30x30 mm
4x M4
48x48 mm
4x M5
Circular hole 58 mm
4x Ø 3,4 mm
Circular hole
88 mm
4x Ø 5,5 mm

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Tightening moments for screw
The screws to be used for assembly must at least satisfy the following conditions:
Standard: VDI 2230
Strength: class 8.8
Surface: galvanized blue, oiled or greased
Thread
Tightening moments
M2
M2,5
M3
0,3 … 0,35 Nm
0,5 … 0,73 Nm
1,1 … 1,4 Nm
M4
2,6 … 3,3 Nm
M5
5,2 … 6,5 Nm
M6
9,0 ... 11,3 Nm
M8
21,6 …27,3 Nm
Table 1: Tightening moments for bolts
2.1.4 Installation in a system
DANGER
The RE rotary modules must not be used in an explosion-
hazardous environment.
WARNING
If add-ons at the RE rotary module could cause danger in con-
nection with moving parts a safe operation must be ensured.
Ensure that the operator cannot reach into the operating range
of the RE rotary module during normal operation.
Ensure that there is no danger to the operator of the system in
special operating modes. The concept depends on the safety
concept of the system and the attached machine parts.

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WARNING
Due to the decentral controller the operator of the RE rotary
module needs not to be near the product so that third persons
might be endangered by the rotation mode.
Lock the controller while you are working on the RE rotary
module and switch the controller only on again after work is
finished.
CAUTION
The RE rotary module is a partly complete machine.
The RE rotary modules must be integrated in the safety concept
of the system so that a safe operation can be ensured.
Ensure that the operating personnel cannot reach into the op-
erating range of the RE rotary modules during operation.
The RE rotary modules may only be operated in accordance
with the intended purpose.
Ensure that the operator cannot reach into the operating range
of the RE rotary module during normal operation. This can be
achieved by taking appropriate safety measures such as cas-
ings, a light grid or by disconnecting the drive from the power
supply.
NOTE
This Montage Instructions should be read carefully before carrying
out any activity on or with the RE rotary modules.

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2.1.5 Preferred combinations to RE-50

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2.1.6 Preferred combinations to RE-75

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3.0.0 Montage Instructions
3.1.0 These Montage Instructions are valid for:
Producte name: Rotary modules electrical
Types: RE-50 I RE-75
RE-50 24V/48V
RE-75 48V
Sequential series: No. 50xxxxxx
This is an incomplete machine
This partly completed machinery must not be put into service until the final machinery
into which it is to be incorporated has been declared in conformity with the provisions
of this Directive 206/42/EG, Annex II B IV where appropriate.
Name and address of the person authorised to compile the relevant technical docu-
mentation: Lanz Beat, PM & Marketing-Services, Afag Automation AG

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3.1.1 Scope of delivery
Quantity
Description
1
Module
2
4
Centering bushings Ø 7x3.mm (RE-50)
Mounting screw M3x22 mm (RE-50)
2
4
Centering bushings Ø 9x4 mm (RE-75)
Mounting screw M4x30 mm (RE-75)
1
Operating Instructions
Table 2: Included in the delivery
3.1.2 Intended use
The RE rotary modules are used for the smooth rotary movement of loads in non-
explosion hazardous ambient and operating conditions that are specified for this
module (see Technical Data).
The RE rotary modules are exclusively intended for rotating useful loads (see Tech-
nical Data) which do neither impair the safety of persons nor present a danger to
property and the environment. Combined with other modules they can be used as a
pick&place station.
NOTE
Any use that exceeds the use mentioned above is regarded as im-
proper.
The manufacturer does not accept any liability for damage resulting
from such use. The risk is that of the user alone.
Intended use also includes paying attention to the Montage Instructions and observ-
ing the maintenance and repair instructions specified by the manufacturer.
CAUTION
The RE rotary module may only be operated and serviced by
correspondingly trained personnel who have also profound
knowledge of the dangers.
The applicable regulations for prevention of accidents and the
other generally accepted safety-relevant and occupational safe-
ty and health regulations are to be followed.

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3.1.3 Warranty
The RE rotary module is designed for 40 million load changes / 2 years
1
operational
performance under the ambient and operating conditions defined for this module (see
“Technical Data”). Load data and design- and acceleration diagrams must be ob-
served.
There are no wearing parts for the RE rotary module!
The warranty includes the replacement or repair of defective module parts at Afag
Automation AG.
When repairs are carried out by the customer without prior training or instruction from
Afag Automation AG the warranty will become void. Any use which exceeds the in-
tended purpose will result in the warranty becoming null and void.
Any further claims are excluded.
3.1.4 Safety
This Montage Instructions should be read carefully before carrying out any activity on
or with the module. The module may only be deployed in accordance with the in-
tended purpose. Modifications on the module that are not described in this Montage
Instructions or have not been approved in writing by Afag are not permitted. In case
of improper changes or assembly, installation, operation, maintenance or repairs,
Afag AG rejects all liability.
CAUTION
Connection of a control system and operation of the RE rotary
module can lead to unpredictable movements which may result
in personal injury or damage to property.
These Montage Instructions should be read carefully before carrying out any activity
on or with the module.
1
whichever occurs first

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3.1.5 Dimension drawing RE-50 / RE-75
Figure 3: Dimension drawing RE-50 / RE-75

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3.1.6 Technical data
Table 3: Technical data RE-50 / RE-75
IP 40 IP 40 IP 40 IP 40

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3.1.7 Rotary module electrical ( without flange)

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3.1.8 Flange rotation