Afag aflex 150 qc Product guide

Flexible feeding system
aflex 150 qc / aflex 200 qc
Operating or assembly instructions
Copyright by Afag GmbH

Page 2 22.10.2019 R01.43
This operating manual is valid for:
Type
Order number
aflex 150 qc
Basis with red back light
50473402
Basis with white back light
50473403
White POM FDA plate for transported material
50473406
Black POM FDA plate for transported material
50473407
aflex 200 qc
Basis with red back light
50473404
Basis with white back light
50473405
White POM FDA plate for transported material
50473410
Black POM FDA plate for transported material
50473411
Type
Order number
aflex
Control
Standard Digital I/O
50473414
Profibus extension
50441875
Ethercat extension
50473417
Profinet extension
50473418

R01.43 22.10.2018 Page 3
Version of this documentation BA_aflex150-200 qc_R01.43_EN.docx
Release: R01.43
Date: 22.10.2019
History
version
changes
R01.2
Documentation of aflex 150 qc and aflex 200 qc. Documentation of the EtherCAT inter-
face
R01.3
Documentation of the Profinet interface
R01.4
Documentation of ControlUnit Firmware v1.40. Improved “direction” control when using
digital inputs.
Changes the user authorization of the MAC filter on the connection page.
R01.41
Minor additions of Profinet description
R01.42
Minor additions of technical plan
R01.43
Warning notice of point 1.3 intended use modified.
Temperature range: 45° instead of 50

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Content:
1Safety instructions............................................................................................ 6
Explanation of symbols and instructions .................................................................................................. 6
Basic safety instructions ........................................................................................................................... 7
1.2.1 Electrical Connection....................................................................................................................... 7
1.2.2 Danger zones................................................................................................................................... 8
Intended use ............................................................................................................................................. 8
Obligations of the operator ...................................................................................................................... 8
2Description of the device................................................................................ 11
General ................................................................................................................................................... 11
Function description................................................................................................................................ 11
Technical data......................................................................................................................................... 12
2.3.1 Maximum size of the parts............................................................................................................ 16
2.3.2 Maximum part weight................................................................................................................... 16
Electrical/Control Components ............................................................................................................... 17
3Installation instructions.................................................................................. 18
Transport ................................................................................................................................................ 18
Assembly of the device............................................................................................................................ 19
3.2.1 Drilling picture for assembly ......................................................................................................... 19
3.2.2 Dimensions of the base plate........................................................................................................ 19
3.2.3 Assembly on base plate................................................................................................................. 20
3.2.4 Dismantling the funnel plate......................................................................................................... 20
3.2.5 Tighten Flex sockets ...................................................................................................................... 21
3.2.6 Remove transport safety............................................................................................................... 22
3.2.7 Install funnel plate......................................................................................................................... 22
Connection of the device......................................................................................................................... 23
Power supply........................................................................................................................................... 24
Connection of the control ....................................................................................................................... 24
3.5.1 Building the control module.......................................................................................................... 25
3.5.2 Electrical Connection..................................................................................................................... 26
4Software description....................................................................................... 28
Installation of the Software .................................................................................................................... 28
User groups............................................................................................................................................. 28
Start page ............................................................................................................................................... 31
4.3.1 Control unit States ........................................................................................................................ 32
4.3.2 Advanced display for Advanced and Administrator user .............................................................. 35
4.3.3 Connection set-up ......................................................................................................................... 37
Main menu.............................................................................................................................................. 37
Control interface ..................................................................................................................................... 41
4.5.1 Aflex control panel ........................................................................................................................ 41

R01.43 22.10.2018 Page 5
4.5.2 Aflex configurations ...................................................................................................................... 44
4.5.3 Backlight........................................................................................................................................ 46
4.5.4 Simulation of the external control ................................................................................................ 47
Sub menu controller................................................................................................................................ 50
Sub menu clients ..................................................................................................................................... 56
4.7.1 Client Nodes Functions.................................................................................................................. 59
4.7.2 T4X Client Node............................................................................................................................. 61
4.7.3 Backlight Node .............................................................................................................................. 64
4.7.4 Profibus Module............................................................................................................................ 66
4.7.5 EtherCAT Module .......................................................................................................................... 67
4.7.6 Profinet Modul .............................................................................................................................. 69
4.7.7 Webserver Profinet ....................................................................................................................... 72
Sub menu Fieldbus configuration............................................................................................................ 74
Sub menu aflex module........................................................................................................................... 78
4.9.1 Test electrical Connection ............................................................................................................. 82
4.9.2 Soft Release Mode ........................................................................................................................ 83
Software update................................................................................................................................. 84
4.10.1 The Bootloader ......................................................................................................................... 84
4.10.2 Software update ControlUnit ................................................................................................... 84
4.10.3 Software update Client Node ................................................................................................... 87
5First commissioning ....................................................................................... 89
Assembly of the system........................................................................................................................... 89
Connect to control unit ........................................................................................................................... 89
Configure ControlUnit ............................................................................................................................. 89
Configure client nodes ............................................................................................................................ 89
Configure software modules ................................................................................................................... 90
Integration with higher control............................................................................................................... 90
5.6.1 Development of transfer values.................................................................................................... 92
5.6.2 Digital input/output ...................................................................................................................... 93
5.6.3 Telnet-Server............................................................................................................................... 101
5.6.4 Profibus module .......................................................................................................................... 104
5.6.5 EtherCAT Module ........................................................................................................................ 107
5.6.6 Profinet Modul ............................................................................................................................ 109
5.6.7 Input commands ......................................................................................................................... 111
5.6.8 Output commands ...................................................................................................................... 113
6Operating manual.......................................................................................... 115
Safety instructions for operation .......................................................................................................... 115
LED Display ........................................................................................................................................... 115
7Maintenance instructions ............................................................................. 118
8Order address................................................................................................ 119
9Disposal ......................................................................................................... 119

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1 Safety instructions
Explanation of symbols and instructions
Symbols: Installation and commissioning shall be done only by qualified personnel
according to operating manual.
Please observe the importance of following explanation symbols and instructions.They
are divided and classified in danger levels according to ISO 3864-2.
DANGER
Indicates a direct potential danger.
When the information is not followed, it can lead to death or sever
body injuries (disability).
WARNING
Indicates a possible threatening situation.
When the information is not followed, it can lead to death or sever
body injuries (disability).
CAUTION
Indicates a possible dangerous situation.
When the information is not followed, it can lead to property dam-
age and mild or indirect body injuries.
INSTRUCTION
Indicated general instructions, useful application-tips and opera-
tion recommendations which however have no impact on the
safety or health of personnel.

R01.43 22.10.2018 Page 7
Basic safety instructions
This operating manual serves as the base to start the flexible feeding device aflex and
to operate it. This operating manual, in particular the safety instructions must be ob-
served which work on or with aflex. Furthermore, the respective valid rules and regu-
lations for accident prevention must be observed for the operation site. The operating
instructions must always be kept at the operation site of the aflex.
The device may only be operated by technically qualified personnel. Qualified person-
nel are persons that are responsible and authorized for the safety of the system due
to their training, experience and teaching, as well as their knowledge of relevant norms,
regulations, accident prevention rules and operating conditions, who carry out the re-
spective required activities and thus identify possible dangers and can avoid them
(Definition for specialists according to IEC 364).
Disturbances that impair the safety of personnel, of aflex or other material assets must
be eliminated immediately.
The following instructions serve not only for the personal safety of the operating per-
sonnel, as well as the safety of the described products and the devices connected to
them:
1.2.1 Electrical Connection
INSTRUCTION
▪Disconnect the voltage supply before assembly or disman-
tling, as well as structural changes.
▪Observe valid accident prevention rules and safety regula-
tions in specific application cases.
▪Check if the working voltage of the device complies with
the local working voltage before commissioning.
▪EMERGENCY-STOP-Equipment must remain effective in all
operating conditions. Unlocking the EMERGENCY-STOP-
Equipment may not ensure uncontrolled restart.
▪The electrical connections must be covered!
▪Protective earth connections must be checked for proper
functioning after assembly.

Page 8 22.10.2019 R01.43
1.2.2 Danger zones
INSTRUCTION
The flexible feeding devices from Afag are built according to EG
machine guidelines, state of the art and the recognized technical
safety regulations. Nevertheless during use, danger to life and
limb of the operators or third parties or impairments to aflex or
other material assets can arise.
Intended use
The aflex serves for the excitation of conveyed goods, in particular piece goods through me-
chanical vibrations. With regard to the maximum permissible dimensions and weights of con-
veyed goods, the instructions in chapter 2.3
Table 1: Technical data
Table 1: Technical data must be observed. Proper use also includes observing all
instructions in the operating manual, as well as observing all safety instructions.
WARNING
The aflex must not be used:
a) In humid and wet areas.
b) At temperatures below 10°C or above 45°C
c) In areas with easily flammable media
d) In areas with explosive media
e) In heavily polluted or dusty environments
f) In an aggressive environment (e.g., saline atmosphere)
Obligations of the operator
A safety-related condition and use of the aflex is the prerequisite for safe operation.
Therefore the operator is obligated to ensure that the following points are complied
with:
Ensure that the aflex is operated by authorized personnel only.
Prohibit hazardous and dangerous work. Check the handling by the staff.
Have the personnel confirm with a signature that the operating instructions have
been understood.
Ensure that a copy of the complete operating manual is permanently accessible at
the aflex.
Check the operating manual regularly for a complete and legible condition.

R01.43 22.10.2018 Page 9
Prescribe appropriate personal protective equipment (PPE) for activities with in-
creased risk of injury.
Pinpoint the responsibilities according to the various tasks, installation, commission-
ing and operation.
You must immediately notify your supervisor personally of any occurring and recog-
nizable malfunctions.

Page 10 22.10.2019 R01.43
INSTRUCTION
All persons working at the aflex as well as persons who are em-
ployed under the Temporary Employment Act have a duty to co-
operate for safety and health protection at the workplace. You
must be instructed about using the aflex.
INSTRUCTION
Reasonably foreseeable misuse, the dangers for the user, third parties
or for the
aflex can bring along with it:
a) The feeding of components whose size and geometry differs
from the size and geometry provided for the aflex
b) Operating the aflex outside the physical application limits de-
scribed in chapter "Commissioning / Operation"
c) Improper assembly, commissioning and operation of the aflex.
d) Changing the control software without prior consultation with
the manufacturer
e) Operating the aflex at or with obvious faults and / or defects.
f) Cleaning work without observing the safety precautions for
aflex work on site.
g) Improper assembly, commissioning and operation of the aflex.
INSTRUCTION
No modifications or alterations to the aflex or the aflex control
may be carried out without the manufacturer's approval.
INSTRUCTION
Any further use or constructional alteration is deemed to be inap-
propriate and will lead to the termination of the warranty claim.

R01.43 22.10.2018 Page 11
2 Description of the device
General
The aflex system consists of an aflex and an external control system. This consists of
individual control modules. A ControlUnit and two drive modules are used in the stand-
ard configuration. Optionally, the control can be extended with additional field bus in-
terfaces.
The aflex control provides following interfaces for superior control:
- Digital input/output
- TCP/IP Telnet
- Profibus (optional)
- EtherCAT (optional)
- Profinet (optional)
Function description
On the aflex, the components are separated and isolated through vibrations. If re-
quired, the components can be conveyed into any areas by defined conveying direc-
tions. These movements must be adapted to the components.
The components are conveyed to the aflex as bulk material. As a rule, a bunker system
is used. The valid tapping coordinates are determined via a camera system and the
component with handling system is removed to the further stations.
An as efficient as possible cycle time implementation of the aflex consists of the fol-
lowing features:
1. The aflex is driven with the least possible drive time. This should be long enough
to re-orient the component. The "flipp" configuration is used for that purpose.
It is more effective to isolate a little many times and take camera pictures in the
mean time to isolate longer.
2. Components are only delivered if are collected in the corner of aflex over many
cycles and large quantities. In all other cases, the components are re-oriented
via flipp impulse (see point 1).
Since during transport the probability of the reorientation to an accessible posi-
tion is small, a short flip pulse is triggered after the transport.
3. The camera detects how many other components can be accessible, the last
accessible component is gripped, the aflex is controlled as soon as the handling
system moves away from the accessible surface.
4. During the switching-on phase of the bunker, the components are conveyed on
the aflex away from the bunker.

Page 12 22.10.2019 R01.43
Technical data
Figure 1: Dimension sheet aflex
Table 1: Technical data aflex qc
Description
Unit
aflex150 qc
aflex200 qc
Dimensions
A
[mm]
210
295
B
[mm]
160
240
C
[mm]
150
220
D
[mm]
100
165
E
[mm]
83,3
106,8
F
[mm]
21
21
G
[mm]
18
18
H
[mm]
12
12
I
[mm]
4
4
J
[mm]
74
93
K
[mm]
17
22
Max. size of the parts & Max. weight of
the parts
See 2.3.1 & 2.3.2
Voltage supply
[V]
24V
24V
Total current [max]
[A]
10 A
10 A
Recommended fuse
C10A / 10A GL T
C10A / 10A GL T
Relative duty cycle of the actuator
[%]
< 15%
< 15%

R01.43 22.10.2018 Page 13
Surrounding temperature
[°C]
0…45°C
0…45°C
Weight
[kg]
4
10,2
Integrated background lighting
optional
optional
Protective type in closed condition
IP51
IP51
Figure 2: Dimension sheet plate for transported material
Table 2 : technical data of plate for transported material
Description
Unit
aflex150 qc
aflex200 qc
Dimensions
A
[mm]
210
295
B
[mm]
160
240
C
[mm]
100
165
D
[mm]
150
220
E
[mm]
21
30
F
[mm]
16,9
26
G
[mm]
12,8
20,30
H
[mm]
16
20
I
[mm]
176
255
J
[mm]
126
200
Weight
[g]
253
854
Table 3: Technical data of the background lighting
Description
Symbol
Unit
Evaluation
Min.
Type
Max.
Working voltage DC smoothed
VCC
[V]
23.0
24.0
25.0
Input current aflex 150
IG
[A]
0.4
0.5
0.7
colouring white
[K]
5600
(Cx=0.33, Cy=0.33 acc. to CIE 1931)
Red wavelength
λ
[nm]
625
634
Surrounding temperature
[°C]
0
45

Page 14 22.10.2019 R01.43
Table 4: Technical data of the control unit
Description
Symbol
Unit
Evaluation
Min.
Type
Max.
Working voltage DC smoothed
VCC
[V]
23.0
DC
24.0
DC
25.0
DC
Input current control unit
IG
[A]
0.064
0.080
4
Reverse polarity protection
Voltage supply
Yes
Signal voltage "1" Digital output
VDO
[V]
VCC –
1.0
VCC
VCC +
0.5
Signal voltage "0" Digital output
VDO
[V]
0
0,002
1
Output current Digital output
IDO
[mA]
4
Input voltage Digital output
VDI
[V]
20.0
24.0
30.0
Input current Digital output
IDI
[mA]
10
10.1
10.5
Reverse polarity protection Digi-
tal input/output
Yes
PWM Power output
VOUT
[V]
VCC -
0.5
VCC
VCC +
0.5
Pulse width Power output
[%]
0
100
Frequency power output
FOUT
[kHz]
39.7
40
40.3
Output current Power output
IOUT
[A]
4
Reverse polarity protection
Power output
No
Operation/Storage temperature
[°C]
+-0 - +40 °C / +-0 - +
85.+°C
Relative humidity
max. 40% without conden-
sation
Protection class
IP 30
Table 5: Technical data of the driver unit T4X
Description
Symbol
Unit
Evaluation
Min.
Type
Max.
Working voltage DC smoothed
VCC
[V]
23.0 DC
24.0
DC
25.0 DC
Input current
IG
[A]
43
6.0
Reverse polarity protection
Voltage supply
Yes

R01.43 22.10.2018 Page 15
Output voltage Output
VOUT
[V]
VCC –
0.5
VCC
VCC + 0.5
Output current Output
IOUT
[A]
4
Pulse width Output
[%]
0
100
Frequency output
FOUT
[Hz]
6
200
Reverse polarity protection
Power output
No
Operation/Storage temperature
[°C]
+-0 - +40 °C / +-0 - + 85.+°C
Relative humidity
max. 40% without condensa-
tion
Protection class
IP 30
Table 6: Technical data of the Profibus module PB node
Description
Symbol
Unit
Evaluation
Min.
Type
Max.
Working voltage DC smoothed
VCC
[V]
23.0
DC
24.0
DC
25.0
DC
Input current
IG
[A]
0.050
0.080
0.120
Reverse polarity protection
Voltage supply
Yes
Operation/Storage temperature
[°C]
+-0 - +40 °C / +-0 - + 85.+°C
Relative humidity
max. 40% without conden-
sation
Protection class
IP 30
Table 7: Technical data of the EtherCAT and the Profinet modules
Description
Symbol
Unit
Evaluation
Min.
Type
Max.
Working voltage DC smoothed
VCC
[V]
23.0
DC
24.0
DC
25.0
DC
Input current
IG
[A]
0.050
0.080
0.120
Reverse polarity protection
Voltage supply
Yes
Operation/Storage temperature
[°C]
+-0 - +40 °C / +-0 - + 85.+°C
Relative humidity
max. 40% without conden-
sation
Protection class
IP 30

Page 16 22.10.2019 R01.43
2.3.1 Maximum size of the parts
A fixed specification of the maximum part size can not be given. The maximum part
size depends on the optimum part number for the process.
This number of parts is to be determined empirically, depending on the orientation
behaviour and the accessible process.
The most stable process is generally achieved when the accessible surface is covered
with components up to a maximum of 2/3.
2.3.2 Maximum part weight
A fixed specification of the maximum part weight cannot be given. The limiting weight
depends on the component geometry and the material. If the components are too
heavy, they cannot be reoriented reliably for the process.
Components should always be tested in advance for suitability.
A non-binding reference to the part size and part weight:
Guidelines for hexagonal nuts DIN 934
aflex150 qc
suitable
aflex200 qc
suitable
M3 –M14
Yes
Yes
M12 (15g, 21.4mm max. diameter)
Yes
Yes
M16 (29g, 23.7mm max. diameter)
No (Accessible sur-
face too small)
Yes
M18 (54g, 29.4mm max. diameter)
No (Accessible sur-
face too small)
Yes

R01.43 22.10.2018 Page 17
Electrical/Control Components
INSTRUCTION
Work on the electrical supply can only be done by qualified per-
sonnel.
Figure 3: Overview of electrical components
- Control Unit: Intelligence and memory of the aflex controller
- Driver units: Outputs for controlling the aflex actuators
- PB-Node: Optional field bus interface
- EtherCAT Node: Optional field bus interface
- Profinet Node: Optional field bus interface
All control modules communicate via a BackSideBus which is mounted in a standard
35x7.5mm DIN rail. DIN rail and BackSideBus are included in the scope of supply.
INSTRUCTION
For reasons of copyright protection, it is not permitted to copy,
modify, decompile and/or decompile the control software and cre-
ate derived programs through it. Exceptions require our express
approval.

Page 18 22.10.2019 R01.43
3 Installation instructions
Transport
The aflex qc may only be transported with the quick-change plate installed.
If control modules are transported individually, the bus contacts mustnot be damaged.
When transporting the control unit in the assembled state, care must be taken to en-
sure a free of play packaging. Otherwise there is a risk that the control modules will
come off the bus rails during transport and carry permanent damage.
The transport packaging supplied must be used.
WARNING
Improper use of transport equipment (floor conveyors, indoor
crane, help aids, slings, etc.) can lead to bruises and other inju-
ries. Required behaviour:
▪Observe and comply with transport and assembly instruc-
tions
▪Use appropriate means of transport

R01.43 22.10.2018 Page 19
Assembly of the device
To enable the aflex to work with reliable functionality, follow the steps below. In case
of non-observance a fault-free operation can not be guaranteed.
3.2.1 Drilling picture for assembly
Figure 4: Drilling picture in assembly level
Table 8: Size for drilling picture
3.2.2 Dimensions of the base plate
The aflex must be mounted on a plate with a minimum weight of 30kg. Otherwise the
performance of the aflex is restricted.
If two aflexs are installed in immediate proximity to one another, care must be taken
that the mounting plates have the stated minimum mass as well as a vibration
decoupling from each other. This decoupling is also applicable if vibrations or shocks
are to be expected by other components of the application.
For vibration decoupling, we recommend detachable damping elements which can
compensate for movements in X-Y-Z directions and are released in total for a mass
of at least 40 kg.
Figure 5: Assembly example in series
Description
aflex150 qc
aflex200qc
Drilling distance X in [mm]
176
261
Drilling distance Y in [mm]
70
110
Diameter of the central bore in [mm]
100
Diameter of the 4 fixing bores in [mm]
12.7 -0,3

Page 20 22.10.2019 R01.43
3.2.3 Assembly on base plate
Insert the aflex with the four Flex bushings into the holes of the system base plate.
Observe the orientation of the device with regard to the subsequent cable connection.
Figure 6: Assembly on base plate
3.2.4 Dismantling the funnel plate
In order to fix the aflex on the base plate, theflex bushings must be tightened. Disman-
tle the funnel plate with the provided plastic wedge.
INSTRUCTION
Please use only the dismantling wedges for the dismantling pro-
cess of the funnel plate!
Insert the wedges into the gap between the white and the red plate.
First, press the two wedges together to tilt them outwards in a rotary movement.
The funnel plate is thereby detached from the magnets and can be removed.