Afag KLF 5 User manual

Linear feeder
KLF 5 / KLF7 / KLF15 / KLF25
Translation of original operating instruction
Copyright by Afag GmbH

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This operation instruction applies to:
Type
Order number
Complete device
Order number
Basic device
Linear
feeder
KLF5
230 V / 50 Hz
15044649
15152773
115 V / 60 Hz
15052019
15087298
Linear
feeder
KLF7
230 V / 50 Hz
15150973
15059714
115 V / 60 Hz
15173186
15125060
Linear
feeder
KLF15
230 V / 50 Hz
15021614
15132435
115 V / 60 Hz
15014508
15165339
Linear
feeder
KLF25
230 V / 50 Hz
15048476
15185736
115 V / 60 Hz
15169958
15006002
Version of Documentation: BA_KLF5-25_R06.1_EN.docx
Release: R06.1
Date: 20/01/2020

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Contents:
1Safety instructions ................................................................................................. 4
1.1 Explanation of symbols and notes ............................................................................................................ 4
1.2 Basic safety information ........................................................................................................................... 5
1.2.1 Electrical hook-up............................................................................................................................ 5
1.2.2 Specific danger points ..................................................................................................................... 6
1.3 Appropriate use ........................................................................................................................................ 6
1.4 Notes for Pacemakers and Defibrillators .................................................................................................. 7
2Description of the device....................................................................................... 8
2.1 General ..................................................................................................................................................... 8
2.2 Functional description............................................................................................................................... 8
2.3 Technical data........................................................................................................................................... 9
3Assembly instructions......................................................................................... 11
3.1 Transport ................................................................................................................................................ 11
3.2 Installing the unit .................................................................................................................................... 11
3.3 Mounting of the linear track................................................................................................................... 12
3.3.1 Attaching one linear track ............................................................................................................. 12
3.3.2 Attaching two linear tracks ........................................................................................................... 13
3.3.3 Attaching split linear tracks........................................................................................................... 14
3.4 Power supply........................................................................................................................................... 15
4Operating instructions......................................................................................... 15
4.1 Linear tracks............................................................................................................................................ 15
4.2 Balancing the masses ............................................................................................................................. 16
4.3 Adjusting the natural frequency ............................................................................................................. 17
4.4 Setting the air gap .................................................................................................................................. 19
5Maintenance instructions .................................................................................... 20
5.1 Troubleshooting and fault repair ............................................................................................................ 20
5.2 Wear parts and spare parts .................................................................................................................... 23
6Accessories .......................................................................................................... 24
6.1 Mounting parts ....................................................................................................................................... 24
6.2 Control device ......................................................................................................................................... 24
6.3 Address for orders................................................................................................................................... 25
7Disposal ................................................................................................................ 25

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1Safety instructions
1.1 Explanation of symbols and notes
Symbols: Assembly and commissioning must be carried out by qualified person-
nel only and according to these operating instructions.
Please observe the meaning of the following symbols and notes. They are grouped into
risk levels and classified according to ISO 3864-2.
DANGER
Indicates an immediate threatening danger.
Non-compliance with this information can result in death or seri-
ous personal injuries (invalidity).
WARNING
Indicates a possible dangerous situation.
Non-compliance with this information can result in death or seri-
ous 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 rec-
ommendations which don’t affect safety and health of the person-
nel.

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1.2 Basic safety information
Familiarity with these basic safety rules and regulations constitutes the fundamental pre-
requisite for safe handling and trouble-free operation of Afag KLF linear feeders.
These operating instructions contain the most significant regulations for safe KLF opera-
tion. These operating instructions - and in particular the safety regulations - must be ob-
served by anyone working on and with the KLF. The applicable on-site accident preven-
tion rules and regulations must also be observed. These operating instructions must al-
ways be kept handy where the KLF is operated.
Operation of the hopper is only to be carried out by technically qualified personnel.
Qualified personnel are deemed to be persons who, by reason of their training, experi-
ence and instructions as well as their knowledge of the prevailing standards, regulations,
accident prevention regulations and operational conditions, have been authorized by the
people responsible for the safety of the system to perform the required activities, and
who are capable of recognizing possible hazards and avoiding them (definition of quali-
fied personnel as per IEC 364).
Any malfunctions that may have an adverse effect on the safety of any persons, the KLF
or other material assets must be eliminated without delay.
The following instructions are not only intended to ensure the personal safety of the op-
erators but also the operation of the products described and the devices connected to
them:
1.2.1 Electrical hook-up
NOTE
▪Disconnect the power supply prior to assembling or dis-
mantling as well as when changing fuses or carrying out
installation modifications.
▪Observe all current accident prevention and safety regula-
tions applicable to particular cases of operation.
▪Check whether the rated voltage of the hopper coincides
with the local power supply prior to putting into operation.
▪All E-Stops must remain effective for all modes of opera-
tion. Unlocking the E-Stops must not, under any circum-
stances, cause uncontrolled restarting of the hopper.
▪The electrical connections must be safeguarded!
▪Ground wires must be checked for proper function subse-
quent to assembly!
▪Hook-up is only to be carried out by authorized personnel.

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1.2.2 Specific danger points
NOTE
Afag KLF linear feeders are state-of-the-art equipment designed in
compliance with the EU Machinery Directive and accepted safety
regulations. Nevertheless, however, risks may arise from using
this equipment that may endanger life and limb of user or third
parties and cause interference with the KLF or other material as-
sets.
1.3 Appropriate use
The KLF is intended exclusively for the transporting and buffering of components and
can also be used for component sorting. For maximum permissible dimensions and
weights of add-on components, observe details in chapter 2.3 Table 1: Technical Data, 3
Assembly instructions and chapter 4 Operating instructions. Appropriate use also in-
cludes observation of all Notes in these operating instructions.
WARNING
The KLF may not be used:
a) in damply and wet area
b) in temperature lower than 10°C or higher than 45°C
c) in areas where readily flammable media are present
d) in areas where readily explosive media are present
e) in heavy polluted or dust- laden area
f) in aggressive area (e.g. saliferous atmosphere)
None modification or reconstruction are allowed. The Tracks (in the chapter 4.1 Linear
tracks and in the chapter 0
Mounting of the linear track) as well as the accessories (chapter 6) are excluded from
this arrangement.
NOTE
Any use other than that described above is deemed to be improp-
er and will cause the warranty to terminate..
Also refer here to our general terms and conditions of sale.

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1.4 Notes for Pacemakers and Defibrillators
Afag vibration conveyors are tested in accordance with regulation 15 of the German Statuto-
ry Accident Insurance Association [Deutsche Gesetzliche Unfallversicherung, DGUV] (previ-
ously BGV B11 of German Accident Prevention Regulations). The permissible values of ex-
posure area 2 are not exceeded, therefore no measures are required pursuant to Section 4
(2) of the DGUV regulation 15. The definitions of Section 12 “Indirect Effects, Medical Im-
plants” remain unaffected by the above.
The alternating magnetic fields that occur in the immediate vicinity of certain vibration con-
veyors may affect the proper functions of active implants, i.e. pacemakers and defibrillators.
Anyone with active medical implants, for which no individual risk assessment has been pro-
vided, must observe the specified safety distances to the vibration conveyors. The distances
each relate to the position of the upper body and the active medical implant relative to the
field source.
Type
Safety Distance
KLF5 / KLF7
--
KLF15
10 cm
KLF25
--

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2Description of the device
2.1 General
Afag KLF linear feeders are used to transport work pieces away from upstream or to-
wards downstream machines. Once various different criteria have been taken into ac-
count, Afag linear feeders may also be used to sort components. The linear feeders may
be integrated into individual feeder stations and complex automated assembly systems.
The various linear feeder types differ in size and range of applications (see chapter 2De-
scription of the device, and chapter 3.3.3 Table 2: Recommended values for maximum work piece widths).
NOTE
KLF feeders are to be operated in conjunction with an Afag control
unit. This is the only combination that will guarantee perfect
transport characteristics.
2.2 Functional description
The KLFs consist of two push-pull vibrating sections arranged next to each other. These
are connected via bifurcated leaf springs to a common base plate where the opposing
vibration forces are virtually cancelled out. Optionally, each of the vibrating sections can
operate as useful or counter mass. Another option is to operate both as useful masses
(see chapter 0
Mounting of the linear track).
A magnet system (armature - magnet core) is built in horizontally between the two vibrat-
ing sections.
The advantages of KLF linear feeders are based on the adjustable balancing of useful
and counter masses that largely eliminates the free vibration forces directly within the
unit.

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2.3 Technical data
Figure 1: Dimensions KLF 5
Figure 2: Dimensions KLF7 -25

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Table 1: Technical Data
Description
Units
KLF5
KLF7
KLF15
KLF25
Dimensions
A
[mm]
150-250
200-400
300-600
500-800
B
[mm]
122
-
-
-
C
[mm]
16
17
24
29
D1
[mm]
4,5
-
-
-
D2
[mm]
5
7
9
10
E
[mm]
36
36
50
60
F
[mm]
49
77
108
135
G
[mm]
61
10
30
45
H
[mm]
28
57,9
99,4
142
K
[mm]
75
127
177
280
M
[mm]
90
140
200
300
N
[mm]
34
-
-
-
P
[mm]
-
4,5
4,5
3
Max. Weight feed rail (armature)
[kg]
0,3
0,65
1,8
3
Difference in weight feed rail - trim weight
[kg]
0
0,1
0,5
0
Weight of basic device
[kg]
0,7
1
2
8,9
Max. Conveying speed
[m/min]
7
7
7
7
Max. power consumption
[VA]
10
15
25
60
Power supply (mains voltage / mains frequency)
[V/Hz]
230/50 or 115/60
Mechanical vibration frequency
[Hz]
Double line frequency (full wave)
Protection class
-
IP54
IP54
IP54
IP54
ambient temperature
[°C]
10-45
10-45
10-45
10-45
Various different sizes are available to suit individual application and spatial require-
ments (see Table 1: Technical Data). The main decision-making criteria, above all, are the
useful / counter masses and the space available for installation. Afag linear feeders are
available with 230V / 50Hz and 115V / 60Hz magnets. Afag also offer a range of control-
lers for the linear feeders (see chapter 6Accessories).

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3Assembly instructions
3.1 Transport
WARNING
Improper use of transport means (industrial trucks, cranes, tech-
nical aids, sling gear etc.) may lead to bruises and other injuries.
Required behaviour:
-Observe and follow the transport and maintenance instruc-
tions
-Proper use of transport means
CAUTION
During transport, the linear feeder must only be held by the base.
The linear track is no lifting point.
3.2 Installing the unit
With the help of the slots in the base plate, the KLF is firmly screwed to the floor (see Fig-
ure 3). This allows for exact definition and adjustability of the junction points at the linear
track intake and outlet. In the horizontal plane the floor should be non-yielding (plate or
block construction) to absorb any residual forces in this plane. Any overhanging profiled
structures must be reinforced with a plate to which the linear feeder will be attached.
Best suited for this purpose is a steel plate at least 20mm thick and more than 120mm
wide. Impacting decisively on floor vibration, vertical vibration forces can be virtually elim-
inated through careful mass balancing (see chapter 4.2 Balancing the masses). Suitable sub-
structures must be provided for height adjustment. Suitable Afag standard parts are
available for complete station extensions in combination with Afag bowl feeders.
Figure 3: Attachment slots in the base plate
Slots for fixing the KLF

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3.3 Mounting of the linear track
3.3.1 Attaching one linear track
The linear track is attached to either vibrating section with the help of an angle bracket or
a lateral plate (see Figure 4 and Figure 5). In the case of the KLF5, the linear track is attached
directly to the vibrating section (see chapter 2.3 Figure 1). In any case, make sure to observe
the correct attachment position as per chapter 2.3 Figure 1 and Fehler! Verweisquelle
konnte nicht gefunden werden.. Any deviations may adversely affect floor vibration.
Figure 4: Linear track mounted with angle bracket
Figure 5: Linear track mounted with lateral plate
Fixing bores for
linear track
Trimming
weight
Left linear track
Lateral plate
Fixing bores for linear
track/trimming weight
Angle
bracket
Trimming weight
Right linear
rack

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The vibrating sections are designed with recesses on the outer side to receive the angle
brackets and trimming weights. The runout height of the linear track can be precisely ad-
justed during initial installation by means of the slot-type bores in the lateral plates. Thus
no track readjustment is necessary when the linear track is removed and reinstalled for
cleaning purposes or change to a different product.
Selection of the linear track location on the left or right is dependent on the installation
and transfer requirements of the upstream and downstream equipment. The linear track
must always be mounted at the inner side of the lateral plate (see Figure 5). The weight of
the linear track (see chapter 4.2 Table 4) and its attachment (angle bracket and/or lateral
plate) must be balanced by a counter mass (trimming weight) mounted to the second vi-
brating section. For a detailed description refer chapter 4.2 Balancing the masses.
NOTE
KLF 5 and KLF 25 require useful and counter masses to be identi-
cal at all times. KLF 7 and KLF 15 require a specific difference to
be adhered to between useful and counter masses. Useful and
counter masses should correspond to the values specified in
chapter 4.2 Table 4.
3.3.2 Attaching two linear tracks
Instead of the trimming weights (see Figure 4 and Figure 5) it is also possible to attach a sec-
ond linear track (see Figure 6). Linear tracks may be attached using angle brackets as well
as lateral plates. Balance the masses as described in chapter 4.2 Balancing the masses.
Figure 6: Linear feeder with two linear tracks Linear
Left vibrating
section
Right vibrating
section
Left vibrating
section
Right vibrating
section

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3.3.3 Attaching split linear tracks
For the purpose of feeding larger work pieces it is possible to provide a linear track de-
sign split in longitudinal direction, attaching each half to the associated vibrating section.
Mass balancing is subject to the rules described in chapter 4.2 Balancing the masses.In
this case, the mass balance impacts on the transport speeds of both linear track sections
and should be adhered to as exactly as possible.
Larger work pieces are transported smoothly as long as these conditions are observed.
Recommended values for max. work piece widths refer Table 2.
Figure 7: Linear feeder with split linear track
Table 2: Recommended values for maximum work piece widths
Type
Max. work piece width
KLF 5
Approx. 30 mm
KLF 7
Approx. 50 mm
KLF 15
Approx. 70 mm
KLF 25
Approx. 80 mm
Split linear track with
angle attachment
Split linear track with lat-
eral plate attachment

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3.4 Power supply
WARNING
▪Any work performed on the electrical supply may only be
performed by trained, authorised, qualified personnel!
▪The power supply must be protected by an FI switch (pro-
vided by the customer).
▪The linear feeder may only be operated with the power sup-
ply specified on the name plate.
The control device IRG1-S is used for the activation of the linear feeder. The MSG801 or
MSG802 can also be used. Please note that an additional CEE connector plug is re-
quired for the MSG controllers (Order number: 11006982)
Installation of the plug is only to be carried out by technically qualified personnel.
Figure 8: End of the wire for additional plug
4Operating instructions
The first step in adjusting the linear feeders is always to balance the masses and then to
adjust the natural frequency.
4.1 Linear tracks
The linear tracks must be unyielding so that the transport pulses generated by the unit
are fully transferred to the work pieces and no superimposed natural vibration can ad-
versely affect the transport process. This requirement has priority over mass reduction
measures. The preferred material for linear tracks is tool steel (e.g. 1.2842, 90MnCrV8).
Linear track design should adhere to the useful masses specified in chapter 2 Table 1
and/or chapter 4.2 Table 4: Recommended values for useful and counter masses with
mass difference.
The following linear track cross sectional dimension ratio is recommended:
𝑊𝑒𝑖𝑔ℎ𝑡
𝑊𝑖𝑑𝑡ℎ =2 1

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The recommended dimensions are listed in Table 3: Linear track dimensions. The di-
mensions are for one vibrating section and can be applied to each of the two vibrating
sections.
Table 3: Linear track dimensions
KLF5
KLF7
KLF15
KLF25
Length [mm]
250
400
600
800
Width [mm]
17
17
24
29
4.2 Balancing the masses
As a consequence of the push-pull principle, Afag linear feeders virtually balance the vi-
bration forces in the basic unit. However, this balance of vibration forces is ensured only
if useful and counter masses are adjusted to each other as precisely as possible. For the
linear feeders KLF 5 and KLF 25, this means that useful and counter masses must be
identical. KLF 7 and KLF 15 require a specific mass difference to be adhered to between
armature and magnet side. Table 4 below lists the armature side as the useful side so
that there is a higher mass available for linear track design. Where the available space
requires the linear track to be attached only to the magnet side of the serial unit, rear-
range the magnet system so that the armature is on the magnet side and vice versa. In
that particular case readjust the air gap afterwards as per chapter 4.4 Setting the air gap
resumes validity after these steps have been performed.
The useful mass (i.e. the linear track mass) is the total weight of all components attached
to the linear track side, including lateral plate or angle bracket. Accordingly, the counter
mass is the total of all individual weights of the components on the counter side including
lateral plate or angle bracket.
Mass balance is checked through simple weighing of useful and counter masses. Any
additional weights required to reach the masses specified in Table 4 must be attached in
such a way that the distance between the mass centre points of useful and counter
masses, viewed in a direction transverse to the transport direction, is as close as possi-
ble. In other words, if possible, the additional masses should not protrude laterally be-
yond the linear feeder as this would lead to increased residual vibration in the floor.
The masses are precisely balanced when hardly any vibrations are noticeable in the floor
and the transport speed of a item freely placed upon the linear track or counter mass, is
identical on both vibrating sides.
Table 4: Recommended values for useful and counter masses with mass difference
Type
Useful mass [kg]
(Armature side)
Counter mass [kg]
(Magnet side)
Difference [kg]
KLF 5
0,30
0,30
0,000,02
KLF 7
0,65
0,55
0,100,02
KLF 15
1,80
1,30
0,500,03
KLF 25
3,00
3,00
0,000,05

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NOTE
Useful and counter masses should correspond to the values
specified in table 4
NOTE
1. Masses are fully balanced if hardly any vibrations are no-
ticeable in the floor.
2. When masses are fully balanced, the transport speeds at
useful and counter sides are identical.
4.3 Adjusting the natural frequency
The Afag linear feeder is a spring- mass vibration system that operates utilising the reso-
nance behaviour. Any changes in the mass require adjustment of the spring stiffness.
For this purpose, sliding adjustment plates are provided on the spring assembly attach-
ment at the base plate (see Figure 9). Sliding these adjustment plates sets the natural fre-
quency.
Figure 9: Spring assembly with adjustment plates
The linear feeder must always be adjusted 'subcritically', in other words, the natural
frequency must be approximately 5 % above the exciter frequency. For a 100Hz feeder
this translates to a natural frequency of around 104Hz, for a 120Hz feeder to one around
126Hz.
Adjustment plates

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The adjustment procedure is as follows:
Place one test component on the linear track and switch on the controller. Use the rotary
button to reduce the transport speed of the linear feeder until the component on the line-
ar track moves only slowly. Keeping the controller setting constant, slowly loosen the
screws of the adjustment plates at one linear feeder spring assembly (see Figure 9). Check
the speed at which the test component is transported while the screws are being loos-
ened. If the transport speed briefly increases initially and then decreases again as the
screws are further loosened, the linear feeder is correctly adjusted and the natural fre-
quency is slightly above the exciter frequency. The adjustment plates must be returned
to the position they were in before the screws were loosened.
If the transport speed increases while the screws are loosened, and decreases only
slightly or not at all when the screws are fully loosened, the linear feeder is adjusted too
tightly and its natural frequency is too high. In this case, move the adjustment plates
down or remove a leaf spring as required if the weight deviation is too great. Then repeat
the test.
If the transport speed decreases immediately while the screws are being loosened, the
linear feeder adjustment is too soft. In this case, move the adjustment plates up or install
an additional leaf spring as required. Then repeat the test.
Make sure when sliding the adjustment plates that they are always horizontal and always
arranged exactly opposite each other.
Adjustment plates up Natural frequency increases
Adjustment plates down Natural frequency decreases
CAUTION
It is vital that the linear feeders be 'subcritically' adjusted (i.e. the
natural frequency must be about 5% above the exciter frequency)
as otherwise the magnet may overheat and burn out, and the
transport speed may decrease as soon as components are placed
upon the linear track.
To avoid the vibrating sections from subsiding, make sure to loosen the adjustment
plates of one spring assembly only at a time during frequency setting.
NOTE
The adjustment plates must be aligned horizontally. The top edg-
es must always be arranged opposite each other.

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4.4 Setting the air gap
During serial assembly, the air gap of the magnet system is set to the values specified in
Table 5. If it deviates from the values specified in Table 5, after adjusting natural fre-
quency, for example, the air gap must be readjusted. For this purpose loosen the lateral
armature fixing screws and reset the air gap with the help of a spacer (see Figure 10).
Figure 10:Armature attachment
The values specified in Table 5 apply only to the associated power supply. It is absolute-
ly vital to ensure during adjustment that the faces of magnet core and armature are
aligned exactly parallel to each another. To achieve the necessary precision, tighten the
screws step by step and in turns.
Table 5: Setting values for the air gap between armature and magnet core
Type
Power supply
Air gap value [mm]
Tolerance range [mm]
KLF5
230 V / 50 Hz
0,8
± 0,05
115 V / 60 Hz
0,6
± 0,05
KLF7
230 V / 50 Hz
0,8
± 0,05
115 V / 60 Hz
0,6
± 0,05
KLF15
230 V / 50 Hz
1,0
± 0,05
115 V / 60 Hz
0,6
± 0,05
KLF25
230 V / 50 Hz
0,8
± 0,05
115 V / 60 Hz
0,6
± 0,05
CAUTION
Setting an air gap larger than specified may cause the magnet to
overheat and the coil to burn out. It is therefore vital that the spec-
ified air gaps be adhered to.
Screw
Air
Armature

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5Maintenance instructions
A type KLF linear feeder is basically maintenance-free. The leaf springs, however, may
oxidise in certain conditions of use, thus affecting the vibration behaviour in the long run.
In such cases the leaf springs may need to be removed and cleaned or to be replaced.
Make sure to always dismantle one spring assembly only as the vibrating sections are
otherwise displaced and trouble-free functioning is no longer guaranteed.
CAUTION
The leaf springs must not be oiled or greased as this would make
the springs sticky and in turn adversely affect the vibration re-
sponse.
5.1 Troubleshooting and fault repair
Conveyor does not run, there is no vibration detectable
Cause of fault
Fault repair
Supply voltage too low or instable, e.g.
only 180 V
Check the supply voltage, readjust the conveyor to
the existing supply voltage, if necessary
Connection to the power supply interrupt-
ed
Check the connection between drive control unit and
control mains adapter
Control unit is switched off <0>
Switch on the control unit <1> or check the jam con-
trol signal if a jam control is used
Control unit is defective
Electrical check of the device, use an exchange or a
replacement unit
The magnet is damaged, the field winding
has burnt out
Electrical check of the magnet, replace damaged
magnet. Check settings: 50 Hz position, full wave
(exciting frequency = 100 Hz)
The air gap between magnet and rotor is
too small (striking) or too large
Set the air gap according to the operating manual
Foreign part jammed in the air gap be-
tween magnet and rotor
Remove foreign part
Conveyor runs too slowly, there is no movement recognisable
Cause of fault
Fault repair
Supply voltage too low or instable, e.g.
only 180 V
Check the supply voltage, readjust the conveyor to
the existing supply voltage, if necessary
Output frequency of the control unit is set
improperly
Set the switch in the control unit according to the re-
quired frequency: 50 Hz position, full wave (exciting
frequency = 100 Hz)
The conveyor rail is not sufficiently fas-
tened to the corresponding drive
Tighten fastening screws, check thread, if necessary